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CONTENTS
ABBREVIATIONS..............................................................................................................................6
1

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

INTRODUCTION............................................................................................................ 12

2.1

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

2.2

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

2.2.1

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

2.2.2

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


2.3

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

OBJECTIVE ................................................................................................................... 19

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

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

5.1

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

5.2

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

5.3

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

5.4

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

5.4.1

Compositions ................................................................................................................................ 24

5.4.2

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


5.5

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

5.5.1

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

5.5.2

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


6

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

6.1

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

6.2

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

6.3

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

6.4

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

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6.5

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

6.5.1

10 Pipeline Farha to Saiwan ........................................................................................................ 34

6.5.2

Oil Transfer Booster Pumps (221-PA-002A/B/C) & Oil Transfer Pumps (221-PA-001A/B/C) ....... 35
7

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

7.1

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

7.2

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

7.3

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

7.4

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

7.5

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

7.5.1

16 Pipeline Saiwan to Alam ......................................................................................................... 38

7.5.2

Oil Transfer Booster Pumps (220-PA-002A/B/C) & Oil Transfer Pumps (220-PA-001A/B/C) ....... 38
8

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

8.1

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

8.2

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

8.3

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

8.4

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

8.5

Nitrogen ................................................................................................................... 44

8.6

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

8.7

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

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

9.1

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

9.2

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

9.3

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

9.4

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

9.5

Nitrogen ................................................................................................................... 51

9.6

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

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9.7

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

10

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

11

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

12

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

13

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

13.1

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

13.1.1

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

13.1.2

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

13.2

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

13.2.1

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

13.2.2

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

13.3

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

13.4

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

13.4.1

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

13.4.2

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

13.5

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

13.5.1

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

13.5.2

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

13.6

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

13.7

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

14

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

15

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

16

REFERENCES ............................................................................................................... 105

17

APPENDICES............................................................................................................... 106

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ABBREVIATIONS
2oo3

2 out of 3

AP

Atmospheric Pressure

BMS

Burner Management System

BOPD

Barrels of Oil per Day

BS&W

Basic Sediment and Water

BVS

Block Valve Station

BWPD

Barrels of Water per Day

C&E

Cause & Effects

CCED

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

CCC

Consolidated Contractor Group of Companies

DB

Distribution Board

DCS

Distributive Control System

DEP

Design Engineering Practice

DG

Diesel Generator

EPF

Early Production Facility

ESD

Emergency Shutdown

ESDV

Emergency Shutdown Valve

FEED

Front End Engineering Design

FG

Fuel Gas

F&G

Fire and Gas

FV

Full Vacuum

GU

Guideline

HAC

Hazardous Area Classification

HMI

Human Machine Interface

HP

High Pressure

HV

High Voltage

IA

Instrument Air

ICS

Integrated Control System

ISO

International Standards Organisation

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JB

Junction Box

KOD

Knock Out Drum

LP

Low Pressure

LPG

Liquefied Petroleum Gas

LT

Level Transmitter

LV

Low Voltage

MCC

Motor Control Centre

MMSCFD

Millions of Standard Cubic Feet per Day

MOV

Motor Operated Valve

MV

Medium Voltage

MVA

Mega Volt Ampere

NPSH

Net Positive Suction Head

OCSP

Operating Control and Safeguarding Philosophy

OHL

Over Head Line

PCV

Pressure Control Valve

PDO

Petroleum Development Oman

PESD

Process Emergency Shut Down

PLC

Programmable Logic Controller

PSV

Pressure Safety Valve

P&ID

Piping and Instrumentation Diagram

PT

Pressure Transmitter

RO

Restricted Orifice

RTU

Remote Transmission Unit

RV

Relief Valve

SCADA

Supervisory Control and Data Acquisition

SDV

Shut Down Valve

SP

Specification

SR

Switch Rack

TCV

Temperature Control Valve

TP

Tie-in Point

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TRV

Thermal Relief Valve

TSV

Thermal Safety Valve

TT

Temperature Transmitter

UCP

Unit Control Panel

UG

Underground

UPS

Uninterrupted Power Supply

WC

Water Cut

VEC

Value Engineering Centre

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1

EXECUTIVE SUMMARY

Adequacy checks were carried out by VEC at the order of CCED for the Phase 2B expansion of
Farha and Saiwan Crude Treatment Facilities.

The facilities at Farha and Saiwan each consist of one Separation Train (each Separation Train
consists of one Separator and one Heater Treater). Under Phase 2B, two additional Separation
Trains are to be added to the existing Farha Facilities and one additional Separation Train is to
be added to the existing Saiwan Facilities. Each additional train is to be a replica of the 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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Farha Plant

Description

Storage Tanks
Off-Spec Tank

Flare System

Vessel Relief Valves


Instrument Air System
Chemical Dosing Packages

Diesel Storage System


Nitrogen

Plot Plan Spacing


Electrical Inadequacy

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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Saiwan Plant

Description
Separators
Storage Tanks
Export Pumps
Export Booster Pumps

Flare System

Vessel Relief Valves

Diesel Storage System


Nitrogen

Plot Plan Spacing

Remarks
Operating outside of Operating
Envelope.
Please see section 7.4 of Report

LP Flare Knockout Drum Inadequate


based on momentum criteria at
inlet nozzle. Also, Production
Separator Train 1 Tailpipe Mach
Number is too high.
1st Train Production Separator and
2nd Train Heater Treater Relief
Valves are inadequate for the fire
case scenario.
Heater Treater Diesel Day Tank is
not adequate based on a 24 hours
supply
Inadequate based on worst case
scenario i.e. No Fuel Gas Available.
Distance between Diesel Unloading
Pump and Diesel Storage Tank is in
adequate. Spacing between the
new 2nd Train Separator and Heater
Treater is not adequate.

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

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2
2.1

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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EPF will be re-routed for treatment at Farha Crude Treatment Facility along with Farha South
Wells Produced Fluids.
In addition to the increased production from Farha and Saiwan wells, CCED wishes to utilise
the crude storage and export facilities at Saiwan Plant to handle stabilised crude from EPFs of
a third newly developed reservoir by the name of SHAHD. The maximum crude production for
all SHAHD EPFs excluding EPF locations H and I is 30,000 BOPD. Produced well fluids from
EPF locations H and I will be processed using the second Saiwan Separation Train which is
part of the additional units envisaged for Phase 2B of the reservoir exploitation program. In
the future, further wells are expected to be drilled and brought online for the SHAHD reservoir
and processed using the second Saiwan Separation Train up to a maximum oil flow of 10,000
BOPD.
The facilities at Farha and Saiwan each consist of one Separation Train (each Separation Train
consists of one Separator and one Heater Treater). Under Phase 2B, two additional Separation
Trains are to be added to the existing Farha Facilities and one additional Separation Train is to
be added to the existing Saiwan Facilities. Each additional Train is to be a replica of the preexisting Separation Trains at Farha and Saiwan.

2.2

Facilities Description

2.2.1

Farha Crude Treatment Facility


The Farha Plant is a sweet facility and has two Inlet Manifolds 201-XY-001A and 201-XY-001B.
Inlet Manifold (201-XY-001A) currently serves Farha EPF but has a provision for routing the
produced well fluids to the Inlet Manifold (201-XY-001B) which serves the main Farha Plant.
This arrangement is necessary as the produced well fluids being treated at Farha EPF will be
required to be re-routed to the main Farha Plant under Phase 2B.
Under Phase 2B, the produced well fluids are to be routed to the Production Separators (201VS-001A/B/C) (Trains 1, 2 and 3) where separation takes place. The separator produced water
is routed to the Evaporation Pond (591-TM-001/002) and the produced crude oil is routed to
the relevant Heater Treater (201-FY-001A/B/C) for dehydration via heat treatment and further

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separation. Each separation train is served by a dedicated Heater Treater unit. The produced
gas from the Production Separators (201-VS-001A/B/C) and Heater Treaters (201-FY001A/B/C) is routed to the Fuel Gas System and any surplus gas from the Fuel Gas System is
diverted to the LP Flare KO Drum (231-VN-001) by way of a Pressure Control Valve (421-PV280) upstream of the Fuel Gas Filter and then routed to the LP Flare (231-FC-001) after
knockout of any entrained liquids. Any produced water from the Heater Treaters is routed to
the Evaporation Pond (591-TM-001/002). The stabilised crude from the Heater Treater Units is
routed to the Crude Oil Storage Tanks (221-TA-001A/B) and then exported using Oil Transfer
Booster Pumps (221-PA-002A/B/C) and Oil Transfer Pumps (221-PA-001A/B/C) to Saiwan
Storage via a piggable 10 Export Pipeline. Gas from the Crude Oil Storage Tanks (221-TA001A/B) is routed to the AP Flare KO Drum (231-VN-002) under pressure control from where it
is routed to the AP Flare (231-FC-002) after knockout of any entrained liquids.
Farha Facility also contains an Off-Spec Oil Tank (221-TA-002) which receives off-spec oil from
AP and LP Flare KO Drums (231-VN-001 & 231-VN-002), Closed Drain Drum (551-VA-001) and
Heater Treaters (201-FY-001A/B/C). The off-spec oil is routed to the inlet header of the
Production Separators (201-VS-001A/B/C) (Trains 1, 2 and 3). All skids are connected to the
Closed Drain System.
Figure 2.2.1.1 overleaf shows an overview of the Farha Crude Treatment Facility.

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Figure 2.2.1.1: Farha Facility Overview
PV

ATM FL
LF

FG
LF

FG

SET @ 8 BARG
LF

SET @ 6 BARG
LF

221-TA-002
Off-spec Oil Tank

INLET MANIFOLD 201-XY-001A/B

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

LF = Low Pressure Flare


AF = Atmospheric Flare
FG = Fuel Gas System
PW = Produced Water
LC = Level Control Valve
PV = Pressure Control Valve
FC = Flow Control Valve

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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2.2.2

Saiwan Crude Treatment Facility

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

ATM FL
LF

FG
LF

FG

SET @ 8 BARG
LF

SET @ 6 BARG
LF

INLET MANIFOLD 200-XY-001A

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

LF = Low Pressure Flare


AF = Atmospheric Flare
FG = Fuel Gas System
PW = Produced Water
LC = Level Control Valve
PV = Pressure Control Valve
FC = Flow Control Valve

SHAHD Crude

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2.3

Station Production Capacities Phase 2B

Required station production capacities considering Phase 2B expansion for Farha and Saiwan
Production Facilities are provided in Tables 2.3.1 and 2.3.2 below.
Table 2.3.1: Farha Facility Required Production Capacities

Description

Farha Production Facility (Scenario 1 Maximum Oil Flow)


Required
Required Production
Required Production
Production
Capacity with 10 %
Capacity with 20 %
Capacity
Overdesign on Flow
Overdesign on Flow

Oil Production from 3 Separation Trains


for Export to Saiwan Storage Tanks
Gas to Fuel Gas System from 3 Separation
Trains
Gas to Flare from Storage Tanks
Produced Water from 3 Separation Trains
(Scenario 2 Max Water from 3
Separation Trains)

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

Table 2.3.2: Saiwan Facility Required Production Capacities


Saiwan Production Facility (Scenario 2 - Maximum Overall Flows)
Production Capacity
Production Capacity
Production with 10 % Overdesign with 20 % Overdesign
Description
Capacity
on Flow
on Flow
Oil Production from 2 Separation
Trains (Saiwan + SHAHD)
20000
22000
24000
Gas to Fuel Gas System from 3
Separation Trains
5.66
6.226
6.792
Gas to Flare from Storage Tanks
0.5
0.55
0.6

Units
BOPD
MMSCFD
MMSCFD

Produced Water from 2 Separation


Trains
SHAHD Crude to Storage Tanks

28000
30000

30800
33000

33600
36000

BWPD
BOPD

Total Crude for Export to Alam Station


after Flashing in Atm. Storage Tanks

71000

78100

85200

BOPD

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3

OBJECTIVE
The objective of this document is to establish and determine the adequacy of the existing
facilities considering the Phase 2B expansion which will see two additional Separation Trains
added to the Farha Crude Treatment Plant and a single additional Separation Train added to the
Saiwan Crude Treatment Plant.

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

FARHA & SAIWAN PLANT PROCESS SIMULATIONS


Objective of Simulation
The objective of the simulation is to form a basis for developing operating envelopes for the
main process vessels and pumps in addition to carrying out calculations for adequacy checks
of main headers, utilities and a basis to carry out Pipesim hydraulic simulations for the Export
Pipelines.

5.2

Farha Simulation Description


The process was modelled as a two stage separation flash with three separation trains
operating in parallel. Each separation train consists of a Separator and a Heater Treater unit.
The Heater Treater acts as the second stage of separation whereby the Separator produced oil

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is heat treated to aid the second stage of separation. The Heater Treater produces gas and
stabilised oil with very little or no produced water.
The unsaturated reservoir fluid is flashed at reservoir conditions and then mixed with water at
reservoir conditions to obtain a flowline composition to the plant. Volumes of unsaturated
reservoir fluid and water used were such as to fit the plant production profile defined by the
two scenarios as per CCED work instruction number CCED-WI-14-629-021 Rev.02R1 and
detailed in Section 5.5 of this study report.
The plant production profile GOR was not forced within the simulation to obtain volumes as
defined by CCED work instruction number CCED-WI-14-629-021 Rev.02R1. The reservoir fluids
were simply allowed to flash at the normal operating conditions within the Separators (8
Barg), Heater Treaters (6 Barg) and Atmospheric Storage Tanks and the volume of gas
produced was accepted as the final gas production volumes for the facility. Produced gas from
Separators and Heater Treaters was considered as the normal gas supply to the Fuel Gas
System and produced flashed gas from the Atmospheric Storage Tanks was considered as gas
to be normally flared.
Figure 5.2.1 overleaf shows the simulation PFD for Farha Crude Treatment Facility.

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Figure 5.2.1: Farha Simulation PFD

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5.3

Saiwan Simulation Description


The process is modelled as a two stage separation flash with two separation trains operating
in parallel. Each separation train consists of a Separator and a Heater Treater unit. The Heater
Treater acts as the second stage of separation whereby the Separator produced oil is heat
treated to aid the second stage of separation. The Heater Treater produces gas and stabilised
oil with very little or no produced water.
For Saiwan Crude Treatment Facility, two different compositions of reservoir fluids were used
namely, SHAHD and Saiwan East (one per separation train). The unsaturated reservoir fluid
was mixed with water at reservoir conditions to obtain a flowline composition to the plant.
Volumes of unsaturated reservoir fluids and water used were such as to fit the scenarios
defined by CCED and detailed in Section 5.5 of this study report.
The GOR was not forced within the simulation to obtain any defined value but rather the
reservoir fluids were simply allowed to flash at the normal operating conditions within the
Separators (8 Barg), Heater Treaters (6 Barg) and Atmospheric Storage Tanks and the volume
of gas produced was accepted as the final gas production volumes for the facility. Produced
gas from Separators and Heater Treaters was considered as the normal gas supply to the Fuel
Gas System and produced flashed gas from the Atmospheric Storage Tanks was considered as
gas to be normally flared.
Figure 5.3.1 overleaf shows the simulation PFD for Saiwan Crude Treatment Facility.

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Figure 5.3.1: Saiwan Simulation PFD

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5.4

Base Data and Assumptions

5.4.1

Compositions
Composition for Farha reservoir fluid and data to define pseudo-components was taken from
a PVT report by Schlumberger FS-53 Final PVT 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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Bottomhole
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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Table 5.4.1.2: Farha Compositional Properties of Bottomhole Sample

Table 5.4.1.2: Farha Zero Flash Properties of Bottomhole Sample

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Composition for Saiwan reservoir fluid and data to define pseudo-components was taken from
a PVT Analysis report prepared by Weatherford SE2-(Saiwan East) Final PVT Report 15-072009R4 and shown in Table 5.4.1.3 below.
Table 5.4.1.3: Saiwan Composition

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Composition for SHAHD H & I reservoir fluids and data to define pseudo-components
was taken from a PVT Analysis report prepared by SGS Oman CCED Well SHH-1 Prelim
Report 04-July-2015R5 and shown in Table 5.4.1.4 below.
Table 5.4.1.4: SHAHD Composition

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

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5.4.2

Key Component Conditions

The key component (equipment) operating conditions used for the simulation are as per Table
5.4.2.1 below.
Table 5.4.2.1: Key Component Operating Conditions for Simulation
Description
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

Simulation Cases & Production Profile Scenarios

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

Production Profile Scenarios and Simulation Comparison

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

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

Saiwan Scenario 1 & 2 (Saiwan


Crude)
Flow Deviation (%)

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

Table 5.5.2.3: Saiwan Total Produced Gas


Description
Saiwan Scenario 1
Saiwan Scenario 2

Simulation Total Produced Gas (MMSCFD)


2.6669
6.1581

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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
N/A

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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

SHAHD Production Profile - Max


Combined Values - Reference R7

2591

1214

1.2645

10000

3908

10,000 throughput as an absolute


maximum SHAHD production
figure. Cut same as scenario 1 28.1 %

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

Train 2 Oil Produced


Production
Water
(BOPD)
(BWPD)
2972

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In addition to the production values provided under Section 5.5.2, an additional volume of
30,000 BOPD of SHAHD stabilised crude and approximately 23,000 BOPD of Farha stabilised
crude is added to the Saiwan Storage Tanks for export to Alam Station via the Saiwan Alam
Export Pipeline. PFDsA6&A7 for Farha and Saiwan are to be referenced alongside the Heat and
Mass Balance DocumentA1 and can be found as attachments to this Study Report.

6
6.1

FARHA PROCESS EQUIPMENT


Inlet Manifold (201-XY-001B)
The Inlet Manifold (201-XY-001B) serves the main Farha Crude Treatment Facility and provides
feed input from the wells to the Production Separators (201-VS-001A/B/C).
The Production Header of the Inlet Manifold was evaluated based upon the new worst case
flow (Scenario 1) in order to check the adequacy. Based on the calculationA8 performed, it was
found that the Production Header is adequate to handle the new increased flow. The flow
regime determined is slug and bubble flow. No details were available regarding the length of
the Production Header so a check was made simply using the nominal diameter of Pipe.

6.2

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


All Farha Production Separators process the same well fluids and are operated in parallel to
each other and therefore see the same flow rates with regards to inputs to and outputs from
the Separator.
An operating envelope was developed based upon Scenario 1 which is the worst case with
respect to highest flow rates for both gas and liquid. It was found that the limiting factors are
the gas and liquid nozzle capacities. The upper limit for the gas nozzle capacity is 89500 Sm3/d
and that for the liquid nozzle capacity is 1576 m3/d.

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Based on scenario 1, the Production Separators would be operating within the operating
envelope at a gas capacity of 744.72 Sm3/d and a liquid capacity of 1460.136 m3/d. BS&W data
was not available and therefore the water cut percentage was used to signify BS&W % vol/vol.
The operating envelope chartA10 is attached to this Study Report. The chart contains a black
dot, showing the operating flows of the Production Separator after the addition of 2 identical
separation trains. It is therefore concluded that the Production Separators are adequate for
operation under both scenarios 1 & 2.
The operating envelope was developed in line with API Spec 12J guidelinesR10 and references
are also made to DEPs. The Farha Production Separator MRBR9 was also referenced alongside
P&IDs in order to obtain the required information for input to the operating envelope sheet.

6.3

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


All Farha Heater Treaters process the same crude output from their respective upstream
Production Separators which operate in parallel to each other.
An operating envelopeA11 was developed based upon Scenario 1 which is the worst case with
respect to highest crude oil flow rates. The operating envelope lies between the inlet nozzle
capacity, gas nozzle capacity and liquid nozzle capacity. The Farha Heater Treater GAR11 was
used to obtain information for input to the operating envelope sheet.
Currently, based on scenario 1, the Heater Treater is operating with a liquid flow rate of
1247.52 m3/day and a gas flow rate of 486.24 m3/day. These values are within the established
operating envelope limits and we can therefore conclude that all three Heater Treater units
are adequate for service with respect to the increased production. The operating envelope
chartA11 is included as an attachment to this Study Report.

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6.4

Oil Storage
Farha Plant has two Crude Oil Storage (Tanks 221-TA-001A/B) which are identical in
dimensions and therefore storage capacity. Each has a capacity of 3843 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

Oil Export (Export Pumps & Pipeline)

6.5.1

10 Pipeline Farha to Saiwan

The 10 Export Pipeline from Farha to Saiwan was found to be adequate for the higher flow
scenario 1. PipesimA29 was used to simulate the Export Pipeline and the elevations used were

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as per the elevation file provided by CCEDR12. Pressure drops and velocities were satisfactory
and acceptable. For detailed results, please make reference to the PipeSim simulation fileR14.

6.5.2

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

The volume of crude oil to be exported from Farha to Saiwan (Scenario 1) is the equivalent of
153.6 m3/hr. Each of the Oil Transfer Booster Pumps and Oil Transfer Pumps are already rated
for 73 m3/hr. The pumps will be used based upon a 2 working and 1 standby philosophy.
This means that each pump should be able to pump 76.8m3/hr of crude to Saiwan Storage
Tanks. The new pumping rate is not that much more than the existing rated flow and after
plotting on the original vendor supplied pump curves, it emerged that the pumps were
adequate with little or no difference in specifications. The marked pump curvesA12 are
attached to this Study Report.

7
7.1

SAIWAN PROCESS EQUIPMENT


Inlet Manifold
The Inlet Manifold (200-XY-001A) serves the Saiwan Crude Treatment Facility and provides
feed input from Saiwan East wells to the Production Separators (200-VS-001A/B).
The Production Header of the Inlet Manifold was evaluated based upon the new worst case
flow (10,000 BOPD throughput of Saiwan East Crude) in order to check the adequacy. Based
on the calculationA9 performed, it was found that the Production Header is adequate to handle
the new increased flow. The flow regime determined is slug flow. No details were available
regarding the length of the Production Header so a check was made simply using the nominal
diameter of Pipe.
A second Inlet Manifold (200-XY-001B) will be required to provide SHAHD H & I produced
well fluids to Train 2 of Saiwan Crude Treatment Plant. This would need to be sized during
detailed design of Phase 2B of the expansion project.

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7.2

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


Production Separators at Saiwan, process two types of well-produced fluids. Saiwan East wells
are processed in Train 1 and SHAHD H & I are processed in Train 2. The higher flow rate case
for Saiwan is Scenario 2.
An operating envelopeA13 was developed based upon Scenario 2 which is the worst case with
respect to highest flow rates for both gas and liquid. It was found that the limiting factors are
the gas and liquid nozzle capacities. The upper limit for the gas nozzle capacity is 98400 Sm3/d
and that for the liquid nozzle capacity is 1576 m3/d.
Based on scenario 2, the Production Separator (200-VS-001A) with Saiwan produced well
fluids is to operate outside of the established operating envelope at a gas capacity of 22924.8
Sm3/d and a liquid capacity of 5385.36 m3/d. BS&W data was not available and therefore the
water cut percentage of 70 % was used to signify BS&W % vol/vol.
The operating envelope chartA13 is attached to this Study Report and contains a black dot,
showing the operating flows of the Production Separator after the addition of an identical
separation train. The additional Separator is to be used to process SHAHD produced well
fluids. It is concluded that the Production Separator (200-VS-001A) is inadequate for operation
under both scenarios 1 & 2 for Saiwan East Wells.
The operating envelope was developed in line with API Spec 12J guidelinesR10 and references
are also made to DEPs. The Saiwan Production Separator MRBR8 was also referenced alongside
P&IDs in order to obtain the required information for input to the operating envelope sheet.

The second Production Separator (200-VS-001B) was evaluated using SHAHD produced well
fluids and a similar operating envelopeA14 was prepared. Based on scenario 2, it was found
that the Production Separator (200-VS-001B) is inadequate to handle processing of SHAHD
produced well fluids.

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7.3

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


Operating envelopes were developed for both the Saiwan Heater Treater units and it was
concluded that they are adequate to handle both Saiwan and SHAHD well produced fluids.
Under scenario 2, both are operating within the limits of the defined operating envelopeA15 &
A16

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

input to the operating envelope sheet.

7.4

Oil Storage
Saiwan Plant has two Crude Oil Storage (Tanks 220-TA-001A/B) which are identical in
dimensions and therefore storage capacity. Each has a capacity of 5420 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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The Off Spec Storage Tank is however adequate when considering capacity to be equal to
24hrs of normal crude production based on scenario 2. The capacity for the Off Spec Storage
Tank is 2830 m3, whereas the required capacity based on 24 hrs crude oil production as per
the Process Design BasisR2 is 1667.04 m3.

7.5

Oil Export (Export Pumps & Pipeline)


7.5.1

16 Pipeline Saiwan to Alam

The 16 Export Pipeline from Saiwan to Alam is found to be adequate for the highest peak
flow from Saiwan. PipesimR16 was used to simulate the Export Pipeline and the elevations used
were as per the elevation file provided by CCEDR13. Pressure drops and velocities were
satisfactory and acceptable. For detailed results, please make reference to the PipeSim
simulation fileA30.

7.5.2

Oil Transfer Booster Pumps (220-PA-002A/B/C) & Oil Transfer Pumps (220-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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The marked pump curvesA17 are attached to this Study Report.

8
8.1

FARHA UTILITIES (Excluding Electrical)


Instrument Air System
The total instrument and utility air consumption for Farha Plant is calculated to be 71.56
Nm3/hrA2. This consumption figure takes into account all instrument air requirements for Plant
Control Valves and Shutdown Valves and also Utility Air Consumption for Heater Treater
Burners for the three trains. It also takes into account an additional 10 % for purposes of jet
cleaning during maintenance of plant equipment.

The current capacity of the Instrument Air Package is 70 Nm3/hr and is therefore inadequate.
It is recommended that another Instrument Air Package be employed in order to satisfy the
instrument air requirements and ensuring plant safety and shutdown is not compromised.

8.2

Chemical Dosing Packages


The Demulsifier Package (121-XX-001) is found to be inadequate. Considering the
incorporation of two more separation trains at Farha, the minimum delivery required for the
demulsifying agent is 18 litres per hour. The current dosing pumps are rated at a maximum
flow rate of 15 litres per hour. An additional demulsifier package will be required at Farha
Plant.
The Corrosion Inhibitor Package (121-XX-002) is found to be adequate and no additional
package is required at the Farha Plant considering the incorporation of two additional
separation trains.
For 3 Separation Trains, the total corrosion inhibitor dosing rate is 0.006m3/hr. This equates to
1.008 m3 of corrosion inhibitor requirement for 7 days. The Storage Tank is therefore
adequate based on 7 days storage as per the Process Design BasisR2.

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The total demulsifier dosing rate is 0.018m3/hr. This equates to 3.024 m3 of demulsifier
requirement for 7 days. The Demulsifier Storage Tank is therefore inadequate based on 7 days
storage as per the Process Design BasisR2.

8.3

Diesel Storage System


The Diesel Storage System for Farha is found to be adequate considering the incorporation of
the additional two separation trains except for the Diesel Storage Tank whose capacity is 295
m3 and the required capacity is calculated to be 299.154 m3. The philosophy followed for the
adequacy check is as per the Process Design BasisR2. Table 8.3.1 overleaf shows the calculated
values and corresponding checks.

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Table 8.3.1: Farha Diesel Storage System Evaluation
Diesel Storage - Farha
Description
Diesel Unloading
Pumps (431-PA001A/B)
Diesel Transfer
pumps (431-PA002A/B)
Diesel supply pumps
to HT (201-PD001A/B)
Diesel Storage Tank
Capacity (431-TA001)
Heater Treater
Diesel Day Tank
(201-TA-001)
DG SETS Diesel Day
Tank (431-TA-002)

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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8.4

Flaring System
Following are the assumptions used for the LP Flare study:

The LP Flare modelA28 was configured as per the overall plot planR16 and collection
network using Aspen flare system analyser version 2007.3.

The isometrics for the piping length and fittings inside the Separator and Heater
Treater skid limits were not available at the time of the adequacy check and were
assumed as 3m for tail pipe length and 10m for 4 subheader length.

Maximum allowable back pressure for relief valves fitted with bellows was limited to
30 % of the set pressure and that for conventional relief valves was limited to 10 % of
the set pressure.

Mach number was limited to 0.5 for sub-headers and header, whereas for tail pipes it
was limited to 0.7.

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

Tail pipes were sized for rated flow for each scenario.

Sizing method for vapor was selected as API 1976 and for two-phase flow, sizing
method of API 2000 was adopted for the LP Flare model.

Maximum size of the fire circle encountered for simultaneous fire relief per scenario
was considered as an area of 232 m2 equal to 17.18 m diameter as per API 521
Addendum, May 2008.

Flare Capacity and Backpressure Assessment Scenarios


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

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The maximum size of the external fire zone encountered was calculated and valves relieving
simultaneously to the LP Flare were grouped according to the identified fire zone.
Capacity and backpressure assessment for the LP Flare was based upon the following three
scenarios described below:-

Fire Zone 1 & Scenario 1

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


201-PSV-201A/201B (Heater Treater 1)
421-PV-280 (normal relief from Fuel Gas Control Valve)

Fire Zone 2 & Scenario 2

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


201-PSV-202A/202B (Heater Treater 2)
421-PV-280 (normal relief from Fuel Gas Control Valve)

Fire Zone 3 & Scenario 3

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


201-PSV-203A/203B (Heater Treater 2)
421-PV-280 (normal relief from Fuel Gas Control Valve)
The scenarios consider relief via individual or combination of relief valves depending on the
number of equipment falling into the maximum area of the determined fire zone. Three fire
zones were identified.

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The outcome of these scenarios was checked against the existing flare capacity, the allowable
velocity limit (Mach No) & allowable backpressure limit in the event of simultaneous relief
from RVs to the LP Flare System.
The existing flare capacity of Farha is 25,500 kg/h as per the existing P&ID JS1006-F-F02-0700001 Rev AB.
The Flare System for Farha is found to be adequate except for the LP Flare Knockout Drum
which is inadequate based on momentum criteria at the inlet nozzle. The results can be found
in the summary tablesA24. All vessel Relief Valves are adequate for blocked outlet, except for
the Heater Treater Relief Valves which are inadequate for the external fire case scenario.
The AP Flare capacity is 9140 Kg/hr and is adequate for the maximum relief load to AP Flare
from Crude Oil Storage Tanks for Farha Scenario 1 of 4092 Kg/hr.

8.5

Nitrogen
The Nitrogen System is hugely inadequate with respect to API2000R8. Considering the Storage
Tank 221-TA-001A, a calculationA4 was performed based upon two working and 1 standby Oil
Transfer Booster Pumps (221-PA-002A/B/C) at maximum pumping rates. A summary of the
results is shown in the table below.

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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There is a second Storage Tank (221-TA-001B) which is used as a standby and also the Off-Spec
Tank (221-TA-002) which are to be considered whilst calculating the required nitrogen for
blanketing purposes but considering the current Nitrogen System capacity is 1920 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 11.5 hours.
Further to the above, it is very unlikely that the current Crude Storage Tanks fit the sizing
philosophy for Storage Tanks as per the Process Design BasisR2 i.e. one tank to be sized for 48
hrs of normal production. This would mean further Storage Tanks and therefore a much
greater requirement of nitrogen than what is foreseen above. The Nitrogen System should be
re-sized during the detailed design stage of Phase 2B of the expansion project.

8.6

Utility Water
The utility water adequacy check was carried out based upon a daily utility water consumption
value of 250 litres per day (0.25 m3/day) per user based upon the Process Design 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

Closed Drain System


As per the Process Design BasisR2, the Closed Drain Drum must be sized for the liquid hold up
of one process vessel other than the Crude Oil Storage Tanks. The process vessel with the

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highest volume of liquid hold up is likely to be the Production Separator. Based upon the HighHigh Level of the Production Separator (201-VS-001A), the volume of liquid held up in the
Separator equates to 13.8474 m3. The Closed Drain Drum (551-VA-001) has a capacity of 18.3
m3 and is therefore adequately sized.
Based upon the criteria set for the Closed Drain Pumps (551-PH-001A/B) as per the Process
Design BasisR2, the pump must be able to pump 0.942m3 of liquid from the Closed Drain Drum
within 30 minutes. With a rated flow of 10 m3/hr, the pump is more than adequate to handle
the required pump out criteria for the contained liquid. The volume of liquid held up was
calculated based upon the difference between high liquid level and low liquid level of the
Closed Drain Drum (400mm).

9
9.1

SAIWAN UTILITIES (Excluding Electrical)


Instrument Air System
The total instrument and utility air consumption for Saiwan Plant is calculated to be 59.39
Nm3/hrA3. This consumption figure takes into account all instrument air requirements for Plant
Control Valves and Shutdown Valves and also Utility Air Consumption for Heater Treater
Burners for the two trains. It also takes into account an additional 10 % for purposes of jet
cleaning during maintenance of plant equipment.
The current capacity of the Instrument Air Package is 70 Nm3/hr and is therefore adequate.

9.2

Chemical Dosing Packages


The Demulsifier Package (120-XX-001) and the Corrosion Inhibitor Package (120-XX-002) are
found to be adequate and no additional packages are required at the Saiwan Plant considering
the incorporation of two additional separation trains.

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For 2 Separation Trains, the total corrosion inhibitor dosing rate is 0.008m3/hr. This equates to
1.344 m3 of corrosion inhibitor requirement for 7 days. The Storage Tank is therefore
adequate based on 7 days storage as per the Process Design BasisR2.
The total demulsifier dosing rate is 0.01m3/hr. This equates to 1.68 m3 of demulsifier
requirement for 7 days. The Demulsifier Storage Tank is therefore adequate based on 7 days
storage as per the Process Design BasisR2.

9.3

Diesel Storage System


Constituent equipment for the Saiwan Diesel Storage System are found to be adequate except
for the Heater Treater Diesel Day Tank (200-TA-001), based upon the philosophy as per the
Process Design BasisR2. Table 9.3.1 overleaf shows the calculated values and corresponding
checks.

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Table 9.3.1: Saiwan Diesel Storage System Evaluation
Diesel Storage - Saiwan
Description
Diesel Unloading
Pumps (430-PA001A/B)
Diesel Transfer
pumps (430-PA002A/B)
Diesel supply pumps
to HT (200-PD001A/B)
Diesel Storage Tank
Capacity (430-TA001)
Heater Treater
Diesel Day Tank
(200-TA-001)
DG SETS Diesel Day
Tank (430-TA-002)

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.

Flare Capacity and Backpressure Assessment Scenarios


The capacity and backpressure assessment for the LP Flare Header, Sub-Header and tailpipes
was carried out based on various relief contingencies using Aspen Flarenet version 2007.3.
The maximum size of the external fire zone encountered was calculated and valves relieving
simultaneously to the LP Flare were grouped according to the identified fire zone.
Capacity and backpressure assessment for the LP Flare was based upon the following two
scenarios described overleaf:-

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Fire Zone 1 & Scenario 1


200-PSV-003A/004A (Production Separator 1)
200-PSV-401A/401B (Heater Treater 1)
420-PV-401 (normal relief from Fuel Gas Control Valve)

Fire Zone 2 & Scenario 2


201-PSV-103B/104B (Production Separator 2)
201-PSV-202A/202B (Heater Treater 2)
420-PV-401 (normal relief from Fuel Gas Control Valve)

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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The AP Flare capacity is 4200 Kg/hr and is adequate for the maximum relief load to AP Flare
from Crude Oil Storage Tanks for Saiwan Scenario 2 of 1204 Kg/hr.

9.5

Nitrogen
The Nitrogen System is hugely inadequate with respect to API2000R8. Considering the Storage
Tank 220-TA-001A, a calculationA5 was performed based upon two working and 1 standby Oil
Transfer Booster Pumps (220-PA-002A/B/C) at maximum pumping rates. A summary of the
results is shown in the table below.

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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9.6

Utility Water
The utility water adequacy check was carried out based upon a daily utility water consumption
value of 250 litres per day (0.25 m3/day) per user based upon the Process Design 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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10 FARHA MAIN HEADERS
The Crude Oil, Produced Water & Produced Gas Headers were all found to be adequate with
respect to the increased plant production.
The plant isometrics were used to evaluate lengths and equivalent lengths for fittings were
calculated and used in the final calculation for adequacy.
For the Crude Oil and Produced Gas Headers, scenario 1 flow rate values were used for the
calculation and scenario 2 flow rate values were used for Produced Water Header calculation. For
the Flare Header, please reference Section 8.4 of this Study Report.
Calculation resultsA18,A19&A20 are attached within the appendix of this Study Report.

11 SAIWAN MAIN HEADERS


The Crude Oil, Produced Water & Produced Gas Headers were all found to be adequate with
respect to the increased plant production.
The plant isometrics were used to evaluate lengths and equivalent lengths for fittings were
calculated and used in the final calculation for adequacy.
Scenario 2 flow rate values were used for all Header calculations. For the Flare Header, please
reference Section 9.4 of this Study Report.
Calculation resultsA21,A22&A23 are attached within the appendix of this Study Report.

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12 FARHA & SAIWAN OVERALL PLOT PLAN (Mechanical)
The current Farha Plant operation consists of one Heater Treater and one Separator. As per the
new expansion plan there will be two new Heater Treaters and two new Separators. The spacing
adequacy check is made to include all major equipment within this plant.

Existing Plot Plan Farha.

The cloud marked portion is new space for Farha Plant.

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Space between Major Equipment in Fahra Area.

Distance as per

Equipment

Equipment

Distance Actual

OIL STORAGE TANK 221-TA-

OIL STORAGE TANK 221-TA-001B

56 Meter

30 Meter

OIL STORAGE TANK 221-TA-001

43.86 Meter

30 Meter

OFF-SPEC OIL TANK 221-TA-002

107.7 Meter

30 Meter

Tank 221-TA-001A/B

61.5 Meter

30 Meter

Fire Water Tank 731-TA-001A

Compressor skid 491-VN-002

37.1 Meter

30 Meter

Heater Treater 201-XX-001A

Separator 201-XY-003A

17.4 Meter

15 Meter

Separator 201-XY-003A

Heater treater 201-XX-001B

20 Meter

15 Meter

Heater treater 201-XX-001B

Separator 201-XY-003B

20.85 Meter

15 Meter

Separator 201-XY-003B

Heater treater 201-XX-001C

19.15 Meter

15 Meter

Heater Treater 201-XX-001C

Separator 201-XY-003C

15 Meter

15 Meter

DIESEL STORAGE TANK 431-

End line of all heater treater

36 Meter

30.5 Meter

DIESEL STORAGE TANK 431-

DG SETS DIESEL DAY TANK 431-

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

DG SETS DIESEL DAY TANK 431TA-002


Heater Treater 201-XX-001A

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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Adequate Space for Farha New Trains

For the Existing Separator 201-XY-003A to equipment 201-XX-001B, the centreline distance is 20
meters and the internal clearance is 15.75 meters which is adequate as per Shell Equipment spacing
standard. The table on the previous page indicates the distance between the equipment and the safe
distance. For equipment 201-XX-001B to equipment 201-XY-003B, there is a centreline distance of
20.85 meters and the internal clearance is 16.85 meters which is adequate as per Shell Equipment
spacing standard.
The equipment spacing between 201-XX-003B and 201-XX-001C is 19.15 meters and the free space
available is 15.15 meters. This is sufficient space as per Shell Equipment Spacing Standard and hence
this spacing is acceptable as per standard engineering practice.
The next equipment items to be considered are 201-XX-001C and 201-XX-003C, the centreline
distance is 15 meters but the free space in between the two equipment items is 10.75 meters which is
not sufficient.

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Existing Plot Plan Saiwan
The Saiwan Plant operation currently consists of one Heater Treater and one Separator. As per the
new expansion plan, there will be one new Heater Treater and one new Separator. This adequacy
report is made considering all major equipment items within this plant.

The cloud marked portion is new space for Saiwan.

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Space between Major Equipment in Saiwan Area.

Equipment

Equipment

Distance Actual

OIL STORAGE TANK 220-TA-

OIL STORAGE TANK 220-TA-

001A

001B

OIL STORAGE TANK 220-TA-

OFF-SPEC OIL TANK 221-TA-

001A

002

Heater treater 200-XX-001A

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

DOSING PACKAGE 120-XX-002

17.4 Meter

15 Meter

Heater treater 200-XX-001B

Separator 200-XY-003B

20 Meter

15 Meter

41.5 Meter

30 Meter

42.5 Meter

30 Meter

13.5 Meter

15 Meter

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

Remarks

PA-003A/B
430-TA-001 DIESEL STORAGE Fire & utility Pump house 730TANK

PA-003A/B

DIESEL UNLOADING PUMP

430-TA-001 DIESEL STORAGE

430-PA-001

TANK

DIESEL UNLOADING PUMP

H2S REMOVAL UNIT 330-XX-

430-PA-001

001

H2S REMOVAL UNIT 330-

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

DAY TANK 200-TA-001

DEMULSIFIER DOSING
PACKAGE 120-XX-002

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Adequate Space for Saiwan New Train

In Saiwan, the existing Separator (200-VS-001A) and the Heater Treater (200-FY-001A) is exactly on
the opposite side of the new Separator (200-XY-004B) and the new Heater Treater (200-XY-003C). In
between the two trains (old and new), the space is sufficient as per shell equipment spacing standard.
In the west direction 28.9 meters is available and in the north direction it is 16 meters. Also, in
between the new Separator and Heater Treater, 16.025 meters clearance is available. However, this
does not satisfy the spacing criteria as per best engineering practices.

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13 FARHA AND SAIWAN - C&A ADEQUACY CHECKS
This section provides an overview of the existing Control & Safeguarding Systems at Farha South
Station & Saiwan East Station and reviews the suitability and adequacy of these systems for the
future project and also provides adequacy of existing Control Valves Trim calculation and
conclusions.

13.1

Control and ESD System at Farha South Station

13.1.1 Existing DCS System at Farha South Station

The Existing Farha Control System (DCS System) for Farha South Station is SIEMENS -SIMATIC
PCS 7 Process Control System design Modular S7-400 range. Existing S7-400 System contains
ET 200M I/O communication module, includes with Process Control Function and 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.

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13.1.2 Existing ESD System at Farha South Station

The Existing Farha ESD/FGS System for Farha South Station is SIEMENS -SIMATIC PCS 7 Process
Control System design Modular S7-400 range. Existing S7-400 System contains ET 200M I/O
communication module, includes with Process Control Function and Safety Function.
Farha ESD System has three ESD System Cabinets (IO PANEL - FARHA-IOP-002/003/004) and one
FGS system cabinet (CPU/IO PANEL-731-FG-001). After checking an existing ESD/FGS system
cabinet (CPU/IO PANEL-731-FG-001) there is sufficient spares slots available in Rack for
inclusion of new cards to interface new signals.
The table overleaf shows the Spares in DCS /ESD/FGS system cabinets at Farha South Station.

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S/N

SYSTEM CABINET NO.

SPARE RACKS

SPARE SLOTS

CPU/IO

RACK-2

RACK-B

PANEL-731-FG-001

CPU/ IO

SLOT 7, SLOT 8, SLOT 9, SLOT


10
NO SPARE RACKS AVAILABLE

RACK-C

PANEL-FARHA-IOP-001

SLOT 9, SLOT 10

(DCS SECTION)

RACK-H
SLOT 8, SLOT 9, SLOT 10

CPU/ IO

NO SPARE RACKS AVAILABLE

RACK-F

PANEL-FARHA-IOP-002

SLOT 9, SLOT 10

(ESD SECTION)

RACK-G
SLOT 9, SLOT 10

CPU/ IO

NO SPARE RACKS AVAILABLE

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

SLOT 8, SLOT 9, SLOT 10

(ESD 1 SECTION)

RACK-J
SLOT 8, SLOT 9, SLOT10

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13.2

Adequacy Evaluation at Farha South Station

13.2.1 Existing DCS System at Farha South Station


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

Farha DCS Section Part List

Backup Battery, Type AA, 1.9 Ah (Quantity 4)


: PS1, PS2
Digital input module, DI 32 x DC 24 V (Quantity 3)
: B101,B102,B103
Digital output module, DO 16 x DC 24 V/0.5 A (Quantity 1)
: B204
Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 7): B305, B306, B307, B308,
C301, C302, C303
Analog Output module, AO 8 x4-20mA, HART(Quantity 3)
: C404, C405, C406
RS-485 Bus Connector with Tilted Cable Outlet (without PG port): 1B1,1B2,1C1,1C2
RS-485 Bus Connector with 35 Cable Outlet (with PG port)
: CPU1;CPU2
PROFIBUS FastConnect bus cable, 2-core, shielded (Quantity 10) : CPU2

DCS Module Disposition


Farha DCS Section has Four Racks: RACK A1, RACK A2, RACK B and RACK C. Rack A1 and Rack A2 has
nine slots, Slot 1, 2 reserved for 24 VDC Power Supply, Slot 3,4 reserved for CPU, Slot 5 for CP and Slot
6,7,8,9 are spare slots available. Rack B, Rack C has Active Bus Module for I/O Modules (DI, DO, AI, AO)
4-20 mA HART protocol. Rack B and C communicate with RS-485 Bus Connector with Profibus Link to
Rack A1 and Rack A2.
The following information shows the Spare Channels in Slots of RACK B and C in Farha DCS System
Cabinet (CPU/IO PANEL - FARHA-IOP-001).
Rack B, B101
Rack No. : RACK B
Slot No.
:1
I/O Module : Digital Input Module B101
Channel
: 32CH, 24VDC
Spare
: I2.2, I3.5, I3.6, I3.7
Rack B, B102

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Rack No. : RACK B


Slot No.
:2
I/O Module : Digital Input Module B102
Channel
: 32CH, 24 VDC
Spare
: I4.0, I4.2, I4.4, I4.6, I5.0, I5.2, I5.6, I6.0, I6.2, I6.4, I6.6, I7.0, I7.2, I7.4, I7.5, I7.6,
,
I7.7
Rack B, B103
Rack No. : RACK B
Slot No.
:3
I/O Module : Digital Input Module B103
Channel
: 32CH, 24 VDC
Spare
: I8.0, I8.1, I8.2, I8.3, I8.5, I8.6, I8.7, I9.0, I9.2, I9.3, I9.4, I9.6, I9.7, I10.1, I10.3,
,
I10.4, I10.6, I10.7 I11.0, I11.1, I11.7
Rack B, B204
Rack No. : RACK B
Slot No.
:4
I/O Module : Digital Output Module B204
Channel
: 16CH, 24VDC
Spare
: Q 00.3, Q00.4
Rack B, B305
Rack No. : RACK B
Slot No.
:5
I/O Module : Analog Input Module B305
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW526
Rack B, B306
Rack No. : RACK B
Slot No.
:6
I/O Module : Analog Input Module B305
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW542
Rack B, B307
Rack No. : RACK B
Slot No.
:7

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I/O Module : Analog Input Module B307
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW558
Rack B, B308
Rack No. : RACK B
Slot No.
:8
I/O Module : Analog Input Module B308
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW570, M7+ PIW574
Rack C, C301
Rack No. : RACK C
Slot No.
:1
I/O Module : Analog Input Module C301
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW590
Rack C, C302
Rack No. : RACK C
Slot No.
:2
I/O Module : Analog Input Module C302
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW606
Rack C, C303
Rack No. : RACK C
Slot No.
:3
I/O Module : Analog Input Module C303
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW622
Rack C, C404
Rack No. : RACK C
Slot No.
:4
I/O Module : Analog Output Module C404

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Channel
: 8CH
Signal
: 4-20mA
Spare
: Q7+ PQW638
Rack C, C405
Rack No. : RACK C
Slot No.
:5
I/O Module : Analog Output Module C405
Channel
: 8CH
Signal
: 4-20mA
Spare
: Q7+ PQW654

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

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


Farha DCS1 Section Part List

Digital input module, DI 16 x DC 24 V (Quantity 4)

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

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

DCS1 Module Disposition


Farha DCS1 Section has one Rack: RACK H. Rack H, Slot 1, 2 reserved for RS-485 Bus Connector with
35 Cable Outlet, Rack H has Active Bus Module for I/O Modules (DI, DO, AI) 4-20 mA HART protocol.
Rack H communicates via RS-485 Bus Connector with Profibus Link to DCS section and ESD section.

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The following information shows the Spare Channels in Slots of RACK H in Farha DCS1 System Cabinet
(CPU/IO PANEL - FARHA-IOP-001).

Rack H, H101
Rack No. : RACK H
Slot No.
:1
I/O Module : Digital Input Module H101
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

Rack No. : RACK H


Slot No.
:5
I/O Module : Digital Input Module H105
Channel
: 16CH, 24VDC

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Spare
: All Channels are spare
Rack H, H206
Rack No. : RACK B
Slot No.
:4
I/O Module : Digital Output Module H206
Channel
: 16CH, 24VDC
Spare
: Q02.4, Q02.5, Q02.6, Q02.7, Q03.0, Q03.1, Q03.2, Q03.4, Q03.5, Q03.6, Q03.7
Rack H, H307

Rack No. : RACK H


Slot No.
:7
I/O Module : Analog Input Module H307
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: All Channels are spare

13.2.2 Existing ESD System at Farha South Station


ESD System Cabinet (IO PANEL - FARHA-IOP-002)
Farha ESD Section Part List

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


: F101,G101
Digital output module Fail Safe, DO 10 x DC 24 V/0.5 A (Quantity 12)
: F203F208,
G203208
RS-485 Bus Connector with Tilted Cable Outlet (without PG port)
: 1H1,1H2,

Rack F, F101
Rack No. : RACK F
Slot No.
:1
I/O Module : Digital Input Module F101
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

Rack No. : RACK G


Slot No.
:1
I/O Module : Digital Input Module G101
Channel
: 10CH, 24VDC

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Spare
,
Rack F, F203

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


I1066.5, I1066.6, I1066.7

Rack No. : RACK F


Slot No.
:3
I/O Module : Digital Output Module F203
Channel
: 10CH, 24VDC
Spare
: Q81.1
Rack G, G203
Rack No. : RACK 5
Slot No.
:3
I/O Module : Digital Output Module F203
Channel
: 16CH, 24VDC
Spare
: Q1081.1
Rack F, F204
Rack No. : RACK F
Slot No.
:4
I/O Module : Digital Output Module F204
Channel
: 10CH, 24VDC
Spare
: Q88.7, Q89.0, Q89.1
Rack G, G204
Rack No. : RACK G
Slot No.
:4
I/O Module : Digital Output Module G204
Channel
: 10CH, 24VDC
Spare
: Q1088.7, Q1089.0, Q1089.1
Rack F, F205
Rack No. : RACK F
Slot No.
:5
I/O Module : Digital Output Module F205
Channel
: 10CH, 24VDC
Spare
: Q96.0, Q96.1, Q96.2, Q96.3,
Rack G, G205

Rack No. : RACK G


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

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Channel
Spare
Rack F, F206

: 10CH, 24VDC
: Q1096.0, Q1096.1, Q1096.2, Q1096.3

Rack No. : RACK F


Slot No.
:6
I/O Module : Digital Output Module F206
Channel
: 10CH, 24VDC
Spare
: NO Spares
Rack G, G206
Rack No. : RACK G
Slot No.
:6
I/O Module : Digital Output Module G206
Channel
: 10CH, 24VDC
Spare
: No Spares
Rack F, F207

Rack No. : RACK F


Slot No.
:7
I/O Module : Digital Output Module F207
Channel
: 10CH, 24VDC
Spare
: Q113.0, Q113.1

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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I/O Module : Digital Output Module G208


Channel
: 10CH, 24VDC
Spare
: Q1121.0, Q1121.1

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


Farah ESD Section Part List

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


E301E306

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 No. : RACK E


Slot No.
:1
I/O Module : Redundant Analog Input Module E301
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW1682

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,

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Slot No.
:2
I/O Module : Redundant Analog Input Module E302
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW1698
Rack D, D303
Rack No. : RACK D
Slot No.
:3
I/O Module : Redundant Analog Input Module D303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW714
Rack E, E303
Rack No. : RACK E
Slot No.
:3
I/O Module : Redundant Analog Input Module E303
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 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
: M0+ PIW1720, M1+PIW1722, M5+PIW1730
Rack D, D305

Rack No.
Slot No.

: RACK D
:5

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I/O Module : Redundant Analog Input Module D305


Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+PIW744, M5+PIW746

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

Rack No. : RACK E


Slot No.
:6
I/O Module : Redundant Analog Input Module E306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M0+PIW1752, M5+PIW1762

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


Farah ESD1 Section Part List

Redundant Fail Safe Analog input module, AI 6 x4-20mA,(Quantity 14) : I301I307,


J301J306

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

JS1034-XX-F06-0001.A1

: 1I1,1I2, 1J1, 1J2

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Rack I, I301

Rack No. : RACK I


Slot No.
:1
I/O Module : Redundant Analog Input Module I301

Channel
Signal
Spare
Rack J, J301

: 6CH
: 4-20mA, HART (2 wire)
: M5+PIW794

Rack No. : RACK J


Slot No.
:1
I/O Module : Redundant Analog Input Module J301
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


Slot No.
:3
I/O Module : Redundant Analog Input Module I303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW824, M5+PIW826

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Rack J, J303
Rack No. : RACK J
Slot No.
:3
I/O Module : Redundant Analog Input Module J303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW824, M5+PIW826
Rack I, I304
Rack No. : RACK I
Slot No.
:4
I/O Module : Redundant Analog Input Module I304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW840, M5+PIW842
Rack J, J304
Rack No. : RACK J
Slot No.
:4
I/O Module : Redundant Analog Input Module J304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW1840, M5+PIW1842
Rack I, I305
Rack No. : RACK I
Slot No.
:5
I/O Module : Redundant Analog Input Module I305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW858
Rack J, J305
Rack No. : RACK J
Slot No.
:5
I/O Module : Redundant Analog Input Module J305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1858
Rack I, I306

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Rack No. : RACK I
Slot No.
:6
I/O Module : Redundant Analog Input Module J306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: No Spares
Rack J, J306
Rack No. : RACK J
Slot No.
:6
I/O Module : Redundant Analog Input Module J306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: No Spares
Rack I, I307
Rack No. : RACK I
Slot No.
:7
I/O Module : Redundant Analog Input Module I307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW890
Rack J, J307

Rack No. : RACK J


Slot No.
:7
I/O Module : Redundant Analog Input Module J307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1890

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13.3

Available Space in FES Control Room for System Cabinet and HMI
Farha South Station Control Room has sufficient space for putting new System Cabinets/
Marshalling Cabinets for DCS/ESD/FGS system.

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

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

13.4

Control and ESD System at Saiwan East Station

13.4.1 Existing DCS System at Saiwan East Station


The Existing Saiwan Control System server (DCS System) for Saiwan East Station is SIEMENS SIMATIC PCS 7 Process Control System design Modular S7-400 range. S7-400 System contains
ET 200M I/O communication module, includes with Process Control Function and Safety
Function.

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Saiwan Control System has one DCS System Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).After
checking existing DCS Process Control system cabinets (CPU/ IO PANEL-SAIWAN-IOP-001),
there is sufficient spares slots available for inclusion of new cards to interface new signals.
Existing Marshalling Cabinets at Saiwan East Station Control Room (MARSHALLING PANELSAIWAM-MAR-002/003/004) have spare space for putting new Terminal Board.
13.4.2 Existing ESD System at Saiwan East Station
The Existing ESD/FGS System for Saiwan East Station is SIEMENS -SIMATIC PCS 7 Process
Control System design Modular S7-400 range. S7-400 System contains ET 200M I/O
communication module, includes with Process Control Function and Safety Function.
Saiwan has three ESD System Cabinets (IO PANEL - SAIWAN-IOP-002/003/004). After checking
an existing ESD/FGS system cabinet (CPU/IO PANEL-730-FG-001), there are sufficient spare
slots available in Rack for inclusion of new cards to interface new signals.
The table overleaf shows the Spares in DCS /ESD/FGS system cabinets in Saiwan East Station.

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S/N

SYSTEM CABINET NO.

SPARE RACKS

SPARE SLOTS

CPU/IO

RACK 1

NO SPARE SLOTS
AVAILABLE

NO SPARE RACKS
AVAILABLE

RACK B

PANEL-730-FG-001
2

CPU/IO PANEL - SAIWAN-IOP001


(DCS)

SLOT 9, SLOT 10
RACK C
SLOT 8, SLOT 9, SLOT 10
RACK D
SLOT 9, SLOT 10

CPU/IO PANEL - SAIWAN-IOP002 (ESD)

NO SPARE RACKS
AVAILABLE

NO SPARE SLOTS
AVAILABLE

CPU/IO PANEL - SAIWAN-IOP003(ESD)

NO SPARE RACKS
AVAILABLE

RACK E
SLOT 9, SLOT 10
RACK F
SLOT 9, SLOT 10

13.5

Adequacy Evaluation at Saiwan East Station

13.5.1 Existing DCS System at Saiwan East Station

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


Saiwan DCS Section Part List

Backup Battery, Type AA, 1.9 Ah (Quantity 4)

Digital input module, DI 32 x DC 24 V (Quantity 4)

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

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

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Analog Output module, AO 8 x4-20mA, HART(Quantity 4)

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

RS-485 Bus Connector with 35 Cable Outlet (with PG port)

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

: D401, D402, D403, D404


: CPU1;CPU2

DCS Module Disposition


Saiwan DCS Section has Four Racks: RACK A1, RACK A2, RACK B, RACK C AND RACK D. Rack A1 and
Rack A2 has nine slots, Slot 1, 2 reserved for 24 VDC Power Supply, Slot 3,4 reserved for CPU, Slot
5 for CP and Slot 6,7,8,9 are spare slots available. Rack B, Rack C and Rack D has Active Bus Module
for I/O Modules (DI, DO, AI, AO) 4-20 mA HART protocol. Rack B, C and D communicates with RS485 Bus Connector with Profibus Link to Rack A1 and Rack A2.
The following information shows the Spare Channels in Slots of RACK B and C in Saiwan DCS System
Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).
Rack B, B101
Rack No. : RACK B
Slot No.
:1
I/O Module : Digital Input Module B101
Channel
: 32CH, 24VDC
Spare
: I3.5, I3.6, I3.7
Rack B, B102
Rack No. : RACK B
Slot No.
:2
I/O Module : Digital Input Module B102
Channel
: 32CH, 24 VDC
Spare
: I4.0, I4.1, I4.2, I4.3, I4.4, I4.5, I4.6, I4.6, I5.0, I5.1, I5.4, I5.5, I5.6, I5.7, I7.7
Rack B, B103

Rack No. : RACK B


Slot No.
:3
I/O Module : Digital Input Module B103
Channel
: 32CH, 24 VDC
Spare
: I8.3, I8.4, I9.1, I9.2, I11.1, I11.2, I11.3, I11.4

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Adequacy Check Report


Rack B, B104
Rack No. : RACK B
Slot No.
:4
I/O Module : Digital Input Module B104
Channel
: 32CH, 24 VDC
Spare
: NO Spares
Rack B, B205
Rack No. : RACK B
Slot No.
:5
I/O Module : Digital Input Module B205
Channel
: 16CH, 24VDC
Spare
: Q01.4, Q01.5, Q01.6, Q01.7
Rack B, B306
Rack No. : RACK B
Slot No.
:6
I/O Module : Analog Input Module B306
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW526
Rack B, B307
Rack No. : RACK B
Slot No.
:7
I/O Module : Analog Input Module B307
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW542
Rack B, B308
Rack No. : RACK B
Slot No.
:8
I/O Module : Analog Input Module B308
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW558
Rack C, C301

Rack No.
Slot No.

: RACK C
:1

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I/O Module : Analog Input Module C301
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW574
Rack C, C302
Rack No. : RACK C
Slot No.
:2
I/O Module : Analog Input Module C302
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW590
Rack C, C303
Rack No. : RACK C
Slot No.
:3
I/O Module : Analog Input Module C303
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW606
Rack C, C304
Rack No. : RACK C
Slot No.
:4
I/O Module : Analog Input Module C304
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW622
Rack C, C305
Rack No. : RACK C
Slot No.
:5
I/O Module : Analog Input Module C305
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M7+ PIW638
Rack D, D401

Rack No. : RACK D


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

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Adequacy Check Report


Channel
Signal
Spare
Rack D, D402

: 8CH
: 4-20mA
: Q7+ PQW654

Rack No. : RACK D


Slot No.
:2
I/O Module : Analog Output Module D402
Channel
: 8CH
Signal
: 4-20mA
Spare
: Q7+ PQW670
Rack D, D403
Rack No. : RACK D
Slot No.
:3
I/O Module : Analog Output Module D403
Channel
: 8CH
Signal
: 4-20mA
Spare
: Q5+ PQW682, Q6+PQW684, Q6+PQW686
Rack D, D404

Rack No. : RACK D


Slot No.
:4
I/O Module : Analog Output Module D404
Channel
: 8CH
Signal
: 4-20mA
Spare
: Spare Slot

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

Saiwan DCS1 Section Part List

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


: D107
Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 2): D308,
RS-485 Bus Connector with Tilted Cable Outlet (without PG port): 1H1,1H2,

Rack D, D107
Rack No.

: RACK D

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Slot No.
:7
I/O Module : Digital Input Module D107
Channel
: 16CH, 24VDC
Spare
: I17.6, I17.7, I18.0 to I18.7, I19.0 to I19.7
Rack D, D308
Rack No. : RACK H
Slot No.
:8
I/O Module : Analog Input Module D308
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M1+ PIW642, M2+ PIW646, M4+ PIW648,M5+PIW650,M6+PIW652,M7+PIW654
ESD System Cabinet (IO PANEL - SAIWAN-IOP-002)
Saiwan ESD Section Part List

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


: G101,H101
Digital output module Fail Safe, DO 10 x DC 24 V/0.5 A (Quantity 12)
: G203G208,
H203H208
RS-485 Bus Connector with Tilted Cable Outlet (without PG port)
: 1E1, 1E2, 1F1, 1F2,
1G1,1G2,1H1,1H2

Rack G, G101
Rack No. : RACK G
Slot No.
:1
I/O Module : Redundant Digital Input Module G101
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

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I/O Module : Digital Output Module G203
Channel
: 10CH, 24VDC
Spare
: Q81.0, Q81.1
Rack H, H203
Rack No. : RACK H
Slot No.
:3
I/O Module : Digital Output Module H203
Channel
: 10CH, 24VDC
Spare
: Q1081.1
Rack G, G204
Rack No. : RACK G
Slot No.
:4
I/O Module : Digital Output Module G204
Channel
: 10CH, 24VDC
Spare
: Q89.0, Q89.1
Rack H, H204
Rack No. : RACK H
Slot No.
:4
I/O Module : Digital Output Module H204
Channel
: 10CH, 24VDC
Spare
: Q1089.0, Q1089.1
Rack G, G205
Rack No. : RACK G
Slot No.
:5
I/O Module : Digital Output Module G205
Channel
: 10CH, 24VDC
Spare
: Q96.0 to Q96.5
Rack H, H205
Rack No. : RACK H
Slot No.
:5
I/O Module : Digital Output Module H205
Channel
: 10CH, 24VDC
Spare
: Q1096.0 to Q1096.5
Rack G, G206
Rack No.

: RACK G

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Slot No.
:6
I/O Module : Digital Output Module G206
Channel
: 10CH, 24VDC
Spare
: Q105.1
Rack H, H206
Rack No. : RACK H
Slot No.
:6
I/O Module : Digital Output Module H206
Channel
: 10CH, 24VDC
Spare
: Q1105.1
Rack G, G207
Rack No. : RACK G
Slot No.
:7
I/O Module : Digital Output Module G207
Channel
: 10CH, 24VDC
Spare
: Q112.0, Q112.3, Q112.6, Q112.7, Q113.0, Q113.1
Rack H, H207
Rack No. : RACK H
Slot No.
:7
I/O Module : Digital Output Module H207
Channel
: 10CH, 24VDC
Spare
: Q1112.0, Q1112.3, Q1112.6, Q1112.7, Q1113.0, Q1113.1
Rack G, G208
Rack No. : RACK G
Slot No.
:8
I/O Module : Digital Output Module G208
Channel
: 10CH, 24VDC
Spare
: Q121.1
Rack H, H208
Rack No. : RACK H
Slot No.
:8
I/O Module : Digital Output Module GH08
Channel
: 10CH, 24VDC
Spare
: Q1121.1

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13.5.2 Existing ESD System at Saiwan East Station

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


Farah ESD Section Part List
Redundant

Fail

Safe

Analog

input

module, AI

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

Rack No. : RACK E


Slot No.
:2
I/O Module : Redundant Analog Input Module E302
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)

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Spare
Rack E, E303

: M5+ PIW730

Rack No. : RACK E


Slot No.
:3
I/O Module : Redundant Analog Input Module E303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW746

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

Rack No. : RACK E


Slot No.
:4
I/O Module : Redundant Analog Input Module E304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)

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Spare
Rack F, F304

: M5+PIW762

Rack No. : RACK F


Slot No.
:4
I/O Module : Redundant Analog Input Module F304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1762
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
: M5+PIW778
Rack F, F305
Rack No. : RACK F
Slot No.
:5
I/O Module : Redundant Analog Input Module F305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1778
Rack E, E306
Rack No. : RACK E
Slot No.
:6
I/O Module : Redundant Analog Input Module E306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW794
Rack F, F306

Rack No. : RACK F


Slot No.
:6
I/O Module : Redundant Analog Input Module F306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1794

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Rack E, E307
Rack No. : RACK E
Slot No.
:7
I/O Module : Redundant Analog Input Module E307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW810
Rack F F307

Rack No. : RACK F


Slot No.
:7
I/O Module : Redundant Analog Input Module F307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1810

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

Rack No. : RACK F


Slot No.
:8
I/O Module : Redundant Analog Input Module F308
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1826

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


Farah ESD1 Section Part List

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


H309, H310

JS1034-XX-F06-0001.A1

: G309, G310,

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

: 1I1,1I2, 1J1, 1J2

The following information shows the Spare Channels in Slots of RACK G and H in Saiwan ESD1 System
Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).
Rack G, G309
Rack No. : RACK G
Slot No.
: 19
I/O Module : Redundant Analog Input Module G309
Channel
: 6CH
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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Slot No.
:3
I/O Module : Redundant Analog Input Module I303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW824, M5+PIW826
Rack J, J303
Rack No. : RACK J
Slot No.
:3
I/O Module : Redundant Analog Input Module J303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW824, M5+PIW826
Rack I, Module I304
Rack No. : RACK I
Slot No.
:4
I/O Module : Redundant Analog Input Module I304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW840, M5+PIW842
Rack J, J304
Rack No. : RACK J
Slot No.
:4
Channel
: 6CH
I/O Module : Redundant Analog Input Module J304
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW1840, M5+PIW1842
Rack I, I305
Rack No. : RACK I
Slot No.
:5
I/O Module : Redundant Analog Input Module I305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW858
Rack J, J305

Rack No.
Slot No.

: RACK I
:5

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I/O Module : Redundant Analog Input Module J305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1858
Rack I, I306
Rack No. : RACK I
Slot No.
:6
I/O Module : Redundant Analog Input Module I306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: No Spares
Rack J, J306
Rack No. : RACK J
Slot No.
:6
I/O Module : Redundant Analog Input Module J306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: No Spares
Rack I, I307

Rack No. : RACK I


Slot No.
:7
I/O Module : Redundant Analog Input Module I307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW890

Rack J, J307

Rack No. : RACK J


Slot No.
:7
I/O Module : Redundant Analog Input Module J307
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1890

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13.6

Available Space in SES Control Room for System Cabinet


Saiwan East Station Control Room has sufficient space for putting new System Cabinets/
Marshalling Cabinets for DCS/ESD/FGS system.

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

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13.7

Control Valve Adequacy Check

Farha: New Cv for Control Valves

Max.

Oil/
Liquid

Water/
Liquid

Water/
Liquid

Viscocity of gas (cP)

Vapour Pressure (barg)

Specific Heat Ratio Cp/Cv=K

Mass Density kg/m3

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

Inlet Pressure (barg)

Oil/
Liquid

Norm. Min. Max. Norm. Min. Max. Norm. Min.

HC Gas/
Vapour

21.32

Mass Flow rate (kg/hr)

Process Fluid /State

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

NEW PROCESS CONDITION FARHA

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

170.527 3.361299 3.987

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

2. For normal & maximum controllability, the existing Trim

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

Existing Trim can be re-used.

32

Existing Trim is not suitable for given process data.

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.

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Saiwan: New Cv for Control Valves

Max.

Water/
Liquid

Norm. Min.

Max.

Water/
Liquid

NA

NA

11.898

1095.597

20

27.119 0.01086

NA

1.23999 6.926838 0.965915

NA

NA

16.873

1314.716

5.5

55

27.119 0.01086

NA

27.119 6.647134 0.973976

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

1.23736 6.332174 0.968773

VALVE OPENING %

NA

EXISTING RATED CV

NEW CALCULATED CV

Critical Pressure

27.119 0.01086

Compressibility

20

Mass Density kg/m3

Specific Garvity

Specific Heat Ratio Cp/Cv=K

Vapour Pressure (barg)

4.5

Viscocity of gas (cP)

Operating Temp.(Deg C)

547.7983

Molecular weight

Outelt Pressure(barg)

HC Gas/
Vapour

Inlet Pressure (barg)

HC Gas/
Vapour

Mass Flow rate (kg/hr)

Oil/
Liquid

Norm. Min. Max. Norm. Min. Max. Norm. Min. Max. Norm. Min. Max. Norm. Min.

Process Fluid /State

TAG NO.
200-PV-006A
201-LV-007A
200-LV-402/403

402-PV-401

Oil/
Liquid

Max. Norm. Min.

200-LV--010A

HC Gas/
Vapour

200-LV-404A

200-PV-402

S/N

NEW PROCESS CONDITION SAIWAN

52

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


for minimum controllability.

60
61

2. For normal & maximum controllability, the existing


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

224
91.366

63

136
93.595

75

53.84

54

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


for minimum controllability.

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

2. For normal & maximum controllability, the existing


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

5 1.131

1011

NA

1.011

220.2

8.657

44

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


for minimum controllability.

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

2. For normal & maximum controllability, the existing


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

Existing Trim is not suitable for given process data.

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14 ELECTRICAL ADEQUACY CHECKS

Introduction
As part of Farha & Saiwan Plant Expansion, an adequacy study on the existing electrical system at
Farha & Saiwan was carried out. The study was mainly aimed to check the available spare
capacity and spare feeders at Farha & Saiwan to cater for the proposed additional loads. The
study consists of the following;

Adequacy of Existing Electrical Infrastructure at Farha


The electrical power system at Farha consists of mainly one switch gear room with one
switchboard (921-EM-002).

415V LV Switch Boards, 921-EM-002


The switch board (921-EM-002) at Farha is fed by 3* 1000 kVA 415V DG sets. The whole facility
loads are connected to this switch board. 18 spare feeders of various ratings and 5 vacant
compartments are available on this LV Switchboard. Extension of LV switchboard, 921-EM-002 is
possible with addition of one cubicle at one end as shown in the site visit report.
The proposal is made for the addition of 4*30kW Heater Treater Blowers (2 duty & 2 standby),
3*0.18kW Demulsifier Dosing Pump (2 duty & 1 standby) and an Instrument Air Package of 65kW
as part of Train 2 and Train 3 expansion. All these new electrical equipments shall be electrified
with the suitable spare feeders from the available 18 spare feeders as listed overleaf.

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Sl. No.

Spare feeders

Rating

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

Diesel Generators (DG set) 1000kVA, 415V


In Farha facility, there are three 1000KVA, 415V Generators. All three DG sets are manufactured
by FG Wilson (Engineering) Ltd, United Kingdom, in the year 2010.
Based on available electrical load schedule (Doc. no.: JS1034-F-E-08-0001)A26, the connected plant
peak load including the recently added new loads under other projects is approximately
2105.03kVA (@ 0.8 p.f), whereas the total installed capacity of DG is 3000kVA. The spare
capacity of the plant is 894.97 kVA (@ 0.8 p.f), which is 29.8% of the installed capacity.
Once the new trains (Train-2 & Train-3) get commissioned, then the connected peak load of the
facility will increase to 2232.24kVA (@ 0.8 p.f) and the spare capacity of the plant will be 767.76
kVA (@ 0.8 p.f), which is 25.6% of the installed capacity.

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Electrical Switchgear Room at Farha
Expansion of the containerized switchgear room is not possible, as it will be an obstruction to the
existing piping and nearby located skids.

Adequacy of Existing Electrical Infrastructure at Saiwan


The electrical power system at Saiwan consists of mainly one switchgear room with two
switchboards (920-EM-002 & 920-EM-003).

415V LV Switch Boards, 920-EM-002


This switch board is feeding the whole plant loads except H2S removal unit. There is an availability
of 11 spare feeders of various rating and 3 vacant compartments in this LV Switchboard.
Available spare feeders and spare spaces are listed below.

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

Diesel Generators (DG set) 1000kVA, 415V


In Saiwan facility, there are four 1000kVA, 415V Generators. All four DG sets are manufactured by
FG Wilson (Engineering) Ltd, United Kingdom, in the year 2010.
Based on available electrical load schedule (Doc. no.: JS1034-S-E08-0001)A26, the connected plant
peak load is approximately 1584.47kVA (@ 0.8 p.f), whereas the total installed capacity of DG sets
is 4000kVA. The spare capacity of the plant is 2415.53 kVA (@ 0.8 p.f), which is around 60.4% of
the installed capacity.
Once the new train (Train-2) gets commissioned, then the connected peak load of the facility will
increase to 1685.26kVA (@ 0.8 p.f) and the spare capacity of the plant will be 2314.74kVA (@ 0.8
p.f), which is around 57.9% of the installed capacity.

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Electrical Switchgear Room
Expansion of containerized switchgear room is possible towards only one side; whereas the other
side is totally obstructed with piping. The possible expansion of the containerized switch gear
room is shown in the relevant site visit report.

Conclusion
The following points are concluded from above study:
At Farha

Spare feeders are available on the 415V LV Switchboards at Farha.

Extension of switch board is possible at Farha

The proposed new 4 Heater Treater Blowers, 3 Demulsifier Dosing Pumps and the
Instrument Air Package shall be electrified with the suitable spare feeders from the
available 18 spare feeders.

Once the new trains (Train-2 & Train-3) get commissioned, then the connected peak
load of the facility will increase to 2232.24kVA (@ 0.8 p.f) and the spare capacity of
the plant will be 767.76 kVA (@ 0.8 p.f), which is 25.6% of the installed capacity.

Expansion of switchgear room towards both ends is not possible at Farha.

At Saiwan

Spare feeders are available on the 415V LV Switchboards at Saiwan.

The proposed new 2 Heater Treater Blowers and Instrument Air Package shall be
electrified with the suitable spare feeders from the available 11 spare feeders on
switchboard (920-EM-002).

Extension of LV switchboard (920-EM-002) is possible towards the left side of the


cubicle (Q1) with 2 cubicles.

Once the new train (train-2) gets commissioned, then the connected peak load of the
facility will increase to 1685.26kVA (@ 0.8 p.f) and the spare capacity of the plant will
be 2314.74kVA (@ 0.8 p.f), which is around 57.9% of the installed capacity.

Switchgear room expansion is possible at Saiwan.

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15 RECOMMENDATIONS & CONCLUSIONS
The majority of both Farha and Saiwan Plants are adequate to cater for the increased planned
production. However, some of the equipment will be required to be replaced or added to if the
expansion is to be successful. It is recommended that majority of the changes should be catered for
during the detailed design stage of Phase 2B expansion.
A table of the inadequate items for Farha is presented below:

Description

Storage Tanks
Off-Spec Tank

Flare System

Vessel Relief Valves


Instrument Air System
Chemical Dosing Packages

Diesel Storage System


Nitrogen

Plot Plan Spacing


Electrical Inadequacy

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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A table of the inadequate items for Saiwan Plant is presented below:

Description
Separators
Storage Tanks
Export Pumps
Export Booster Pumps

Flare System

Vessel Relief Valves

Diesel Storage System


Nitrogen

Plot Plan Spacing

Remarks
Operating outside of Operating
Envelope.
Please see section 7.4 of Report

LP Flare Knockout Drum Inadequate


based on momentum criteria at
inlet nozzle. Also, Production
Separator Train 1 Tailpipe Mach
Number is too high.
1st Train Production Separator and
2nd Train Heater Treater Relief
Valves are inadequate for the fire
case scenario.
Heater Treater Diesel Day Tank is
not adequate based on a 24 hours
supply
Inadequate based on worst case
scenario i.e. No Fuel Gas Available.
Distance between Diesel Unloading
Pump and Diesel Storage Tank is in
adequate. Spacing between the
new 2nd Train Separator and Heater
Treater is not adequate.

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16 REFERENCES
R1) CCED work instruction number CCED-WI-14-629-021 Rev.02.
R2) Process Design Basis document number JS1006-X-F06-0501-C2.
R3) Farha PVT Analysis
R4) Saiwan East PVT Analysis
R5) SHAHD H & I PVT Analysis
R6) SHAHD H&I Production Forecast
R7) Saiwan Production Separator MRB
R8) API2000 Nov 2009
R9) Farha Production Separator MRB
R10) API Spec 12J
R11) Farha Heater Treater GA
R12) Farha Pipeline Elevation
R13) Saiwan Pipeline Elevation
R14) Saiwan Heater Treater GA
R15) Farha & Saiwan FG PCV & PSV DataSheets
R16) Farha Overall Plot Plan
R17) Saiwan Overall Plot Plan
R18) API 526
R19) API 521
R20) API 520 Parts 1 & 2

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17 APPENDICES
A1) H&MB FARHA & Saiwan
A2) Farha Control Valves & SDV's
A3) Saiwan Control Valves & SDV's
A4) Blanket Calc 221-TA-001A
A5) Blanket Calc 220-TA-001A
A6) Farha PFD
A7) Saiwan PFD
A8) Farha Manifold Calculation
A9) Saiwan Manifold Calculation
A10) Operating Envelope Farha Separator
A11) Operating Envelope Farha Heater Treater
A12) Farha Booster and Export Pump Curves
A13) Operating Envelope Saiwan Separator Saiwan Crude
A14) Operating Envelope Saiwan Separator SHAHD
A15) Operating Envelope for Saiwan Heater Treater
A16) Operating Envelope for Saiwan HT - SHAHD
A17) Saiwan Booster and Export Pump Curves
A18) Farha Crude Header Calculation
A19) Farha Produced Water Header Calculation
A20) Farha Produced Gas Header Calculation
A21) Saiwan Crude Header Calculation
A22) Saiwan Produced Water Header Calculation
A23) Saiwan Produced Gas Header Calculation
A24) Farha LP Flare Assesment Summary Tables incl RVs

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A25) Saiwan LP Flare Assessment Summary Tables incl RVs
A26) Electrical Load Lists
A27) UniSim Simulations
A28) FlareNet Files - Farha & Saiwan
A29) Farha Pipeline PipeSim
A30) Saiwan Pipeline PipeSim

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