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ASAS Contracting Ltd.

Jihar Gas Plant


GTP
Rehabilitation Phase-II/A

Process Description

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

Introduction
Jihar gas plant is located 45 Km north- west of Palmyra city,designed to process 4,3 MMSCMD of gas
gathered from Jihar and Mahr gas fields, the outcome products are as following:

Export Gas Capacity, MMSCMD 3,9

Oil/Condensate Capacity, m3/day 2130

LPG Capacity, m3/day 360

Jihar Gas Plant was attacked by terrorist armed groups, and was exposed to vandalism resulting of huge
damage in main equipment and piping.

The aim of basic engineering is to develop a new design by modifying the existing one taking into
account maximum exploitation of remaining facilities in good condition or that could be repaired in a
short or medium time, in order to reach the optimum solution for liquid separation, stabilization,
pumping to T4, and gas conditioning and exporting to pipeline.

Scope
The scope of the document is to provide a process description and required modification in the plant
phase II rehabilitation.

Objective
The objective of phase II rehabilitation is treating gas that come fromwellheads JHR-2, JHR-6, JHR-12&
JHR-8 and gas and condensate from SGS’s JIHAR wellheads ( JHR-1,JHR-7,JHR-9,JHR-10,JHR-11) and
MHAR wellheads ( MHR-1,MHR-2,MHR-3,MHR-4 ) to produce enhancing gas by using existing units and
facilities and cross over condensate to stage -II station and inject produced water to injection well, this
gas will be exported via pipeline to gas network .

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

Process description
The equipment and facilities will be included in GTP phase-II rehabilitation:

1- Inlet manifold area 2000


2- HP 2100
3- Test separators 2100
4- Dehydration unit 2400
5- Produced water 2200
6- Fuel gas 2860
7- Flare system 2940
8- Close drain 2920
9- Chemical injection demulsifier 2890
10- Chemical injection methanol 2880
11- Chemical injection CI 2885
12- Hot oil 2700
13- Diesel generator 2960
14- Instrument air system 2870
15- Gas metering system GTP 2590
16- Gas metering skid , STAGE -2 station x-1221

The modification will be in control system, rerouted piping, resizing piping and isolation not used
process systems. All those modification will be detailed during details engineering study.

In the following process description will be focused on the above facilities and the modification which
were mentioned in CFT.

1- Inlet manifold:
PFD JI-191-PR-11-2000-10001-1

P&ID JI-191-PR-12-2000-10001-1
JI-191-PR-12-0000-10011-1
JI-191-PR-12-0000-10012-1
JI-191-PR-12-0000-10013-1
JI-191-PR-12-0000-10014-1
JI-191-PR-12-0000-10004-1+2

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

GTP –Jihar receives well fluids from four wellheads JHR-2, JHR-6, JAZ1.3& JHR-8 and gas and
condensate from satellite gathering stations SGS Jihar and SGS Al Mahr.
The inlet manifold area includes HP, MP and Test header connected to HP, MP and Test separator
respectively. In GTP phase II, HP header will be connected to HP separator, and Test separator will be
used as MP separator.

2- HP separator (V-2101)

PFD JI-191-PR-11-2100-10001-1

P&ID JI-191-PR-12-2100-10001-1+2
JI-191-PR-12-2100-10003-1

HP Separator receives feed from Jihar-2, Jihar-6, Jihar-8 wells, and gas & condensate from SGS-Jihar
and SGS-Al-Mahr, HP separator separates well fluid into gas, condensate and water.
Gas from HP separator flows to Molecular sieve dehydration unit through HP gas cooler (A-2101) (De-
methanizer Reboiler E-2501 and Gas cooler E-2401 will be bypassed).
Condensate from HP separator is mixed with the condensate coming from Dehydration inlet separator
(V-2401), |Dehydration inlet filter coaelescer (F-2401), and Regeneration gas KOD (V-2403) and sent
to Test separator.
Produced water from HP Separator is routed to Produced Water storage tank via produced water header.

3- Test separator (V-2102)

PFD JI-191-PR-11-2100-10001-1

P&ID JI-191-PR-12-2100-10002-1

In GTP rehabilitation phase II/A, Test separator will be used as MP separator. Condensate from HP
separator, Dehydration inlet separator (V-2401), Dehydration inlet filter coaelescer (F-2401), and
Regeneration gas KOD (V-2403) are mixed together and sent to Test separator inlet. and sent to Test
separator. Gas from test separator flows to warm flare header through pressure control valve (Recycle
compressor is not available).
Condensate from Test Separator is routed to stage 2 via Stage 2 oil crossover. Produced water from the
Test Separator along with water from other units is routed to Produced Water Storage Tank via
produced water header.

4- HP Gas cooler (A-2101)

PFD JI-191-PR-11-2100-10001-1

P&ID JI-191-PR-12-2100-10001-2

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

The gas from HP separator is routed to HP gas cooler, which is an air cooled heat exchanger, the outlet
temperature of HP gas cooler will be as low as possible in order to condense the maximum quantity of
water before sending the gas to dehydration unit

5- Dehydration unit
PFD JI-191-PR-11-2400-10001-1
JI-191-PR-11-2500-10001-1
JI-191-PR-11-2500-10002-1
JI-191-PR-11-2500-10003-1

P&ID JI-191-PR-12-2400-10001-1
JI-191-PR-12-2400-10002-1+2+3
JI-191-PR-12-2400-10003-1+2+3
JI-191-PR-12-2400-10004-1
JI-191-PR-12-2400-10005-1
JI-191-PR-12-2400-10007-1
JI-191-PR-12-2400-10008-1+2
JI-191-PR-12-2500-10001-1
JI-191-PR-12-2500-10002-2
JI-191-PR-12-2500-10003-1
JI-191-PR-12-2500-10011-1+2

The function of the dehydration unit is to reduce the water content of the incoming gas to an acceptable
level for gas transportation pipeline. The Dehydration equipment which will be used in GTP Phase II
rehabilitation:
Molecular Sieve Inlet Separator V-2401, Molecular Sieve Inlet Filter Coalescer F-2401, Dehydration
Inlet Heater E-2402, Molecular Sieve Dryer V-2402A/B/C, Dry Gas Filter F-2402A/B, regeneration gas
heater E-2403, regeneration gas cooler A-2401 and Regeneration Gas KO Drum V-2403.
The feed gas of Dehydration Unit, in the original condition, is coming from HP gas cooler A-2101, The
feed gas is cooled by the De-methanizer Reboiler E-2501 from 54.5°C to 47.8°C. Gas is further cooled
by Gas cooler E-2401 from 47.8°C to 27°C. Cooling in E2401 is achieved by propane chilling.
In phase II of rehabilitation project, demethanizer reboiler E-2501 and gas cooler E-2401 will be
bypassed. Dehydration unit inlet gas temperature will be higher than 27°C, this temperature will be
affected by ambient temperature and it will vary accordingly.
Saturated vapor from V-2401 is routed to a Molecular Sieve Inlet Filter Coalescer F-2401 where
entrained droplets of liquid are separated. Wet gas from filter coalesce F-2401 flows to Molecular sieve
dryers and a slip stream is fed to Dehydration inlet heater E-2402 so that the total gas is preheated by
2°C using hot oil, This is done to avoid any retrograde condensation in the molecular sieve beds caused
by pressure drop.
In phase II of rehabilitation project, the inlet gas temperature of dehydration unit will be higher than
27℃ making the inlet gas water content higher than the design water content. To avoid unit overloading,

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

a bypass line will be constructed around dehydration unit to control the amount of wet gas entering the
mol sieve beds, which will help avoiding desiccant damage or lifetime shortening. The bypass line will
be from D/S of dehydration inlet separator V-2401 to D/S of Dry gas filter F-2402 A/B, so that any
condensed liquid is separated before the gas is bypassed.
The Dry gas from molecular sieve beds is filtered by Dry Gas Filter F-2402 A/B in order to remove
desiccant dust and other particles of 1 micron and larger.
The dry gas from F-2402 A/B is sent to D/S of PV-2501-41 via a new constructed line which will
bypass the Gas/Gas Exchanger E-2502.

Regeneration gas is taken from D/S of dry gas filter and compressed by Regeneration Gas Compressor
C-2401A/B (in normal operation condition) so that the gas can be recycled back to U/S of dehydration
unit. Regeneration gas compressors are fully damaged hence, a bypass line will be constructed around
the regeneration compressors, and the regeneration gas will be routed to gas export line. The flow rate of
regeneration gas will be controlled by flow controller acting on flow control valve installed at the outlet
line of regeneration gas KOD V-2403.

Regeneration gas is routed to regeneration gas heater E-2403A/B, regeneration gas temperature will
vary according to regeneration phases (gradual heating, heating and cooling). Regeneration gas enters
the bed that completes the drying cycle (16 hours) from the bottom and leaves it from the top.
Regeneration gas from regeneration bed is routed to regeneration gas cooler where the outlet
temperature is reduced as low as possible to remove excess water and reduce the water content of the
outlet gas. The regeneration gas from Regeneration gas cooler enters Regeneration Gas K.O Drum V-
2403 to separate condensed liquid, then the regeneration gas will be diverted to export line D/S of PV-
2501-41.

The liquid from dehydration unit (from dehydration inlet separator V-2401, Molecular Sieve Inlet Filter
Coalescer F-2401 and Regeneration Gas KO Drum V-2403) will be sent to D/S of Test separator.

6- Fuel gas system


PFD JI-191-PR-11-2860-10001-1

P&ID JI-191-PR-12-2860-10001-1
JI-191-PR-12-2860-10003-1
JI-191-PR-12-2860-10004-1
JI-191-PR-12-2860-10005-1

The fuel gas will be taken from D/S of Dry gas filter F-2402A/B and sent to U/S of PV-2861-12 through
a new constructed line that connects the outlet line of dry gas filter and the original line connected to
Sales gas compressors suction header. Fuel gas pressure is reduced from dry gas pressure (High
pressure) to the operating pressure of HP fuel gas system by means of pressure control valve PV-2861-
12.

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

Gas from D/S of PV-2861-12 is routed to HP fuel gas KOD (V-2861) in order to separate condensed
liquid. HP fuel gas heater E-2861 and HP fuel gas filters F-2861A/B will be isolated during Phase II of
rehabilitation project. Gas from V-2861 is routed to U/S of PV-2862-01 through a new constructed line
then, the gas is sent to LP fuel gas KOD V-2862 to remove condensed liquid. LP fuel gas from V-2862
is routed to LP fuel gas heater E-2862 and LP fuel gas filters E-2862A/B then to LP fuel gas consumers:
1. Ground Flare Pilot Burners
2. Ground Flare Pit Burners
3. HP Cold Flare Header
4. HP Warm Flare Header
5. Ground Flare Header
6. Produced Water Storage Tanks TK-2251A/B
7. Methanol Storage Tank TK-2881A/B, TK-2882, TK-2883
8. Hot Oil Drain Drum V-2703
9. Closed Drain Drum TK-2921
10. Hot Oil Expansion Vessel V-2702.
11. Hot oil heater H-2701.

Liquid from V-2861 and V-2862 is routed to Closed drain vessel V-2921 via level control valves.

1- Produced water unit


PFD JI-191-PR-11-2200-10001-1

P&ID JI-191-PR-12-2200-10010-1
JI-191-PR-12-2200-10011-1+2
JI-191-PR-12-2200-10012-1+2

The Produced water from HP Separator V-2101, Test Separator V-2102 and Open drain pump P-2922A,
is routed to the Produced water header.
Produced water from the header flows to the Produced Water Storage Tank TK-2251A/B through gas
boot V-2251A/B.
From the tanks, the produced water is pumped by new Produced Water pumps to Jihar-5 dry.

2- Flare system

PFD JI-191-PR-11-2940-10001-1

P&ID JI-191-PR-12-2940-10001-1
JI-191-PR-12-2940-10002-1+2
JI-191-PR-12-2920-10003-1
JI-191-PR-12-2920-10007-1
JI-191-PR-12-2920-10008-1

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

a- Ground flare system

The ground flare package consists of two different headers as follows:


1. Gas Relief Header This header receives the relieved gas from the pressure safety valve of
Methanol Storage Tank (TK-2881A/B), Closed Drain Drum (V-2921), Hot Oil Expansion Drum
(V-2702), Produced Water Storage Tank (TK-2251A/B) and Hot Oil Drain Drum (V-2703) and
relives the gas to ground flare pit via gas burner.
2. Mixed Phase Relief Header handles high pressure relive from manifold area. This relive will be
two phase relive. Two phase relive from manifold are is routed to ground flare pit via liquid
burners.

The Ground flare pit consists of High Energy Ignition System (HEIS). The Instrument Air& the LP fuel
gas for the HEIS are supplied from the respective distribution headers.

b- HP Flare system

The HP Flare System consists of HP flare KO Drum (V-2941), HP flare KO Drum pumps (P-2941 A/B)
& a flare stack (Z-2941). The KO Drum receives the relieved hydrocarbon from the warm & cold flare
headers. Cold flare header receives relived gas from PV-2501-36B, XV-2501-05 and XV-2501-12.
Warm flare header receives gas relived from PV-2102-03A and PSVs from all relevant vessels.
The HP flare consists of High Energy Ignition System (HEIS). The Instrument Air & the LP fuel gas for
the HEIS are supplied from the respective distribution headers.

3- Close drain system:


PFD JI-191-PR-11-2920-10001-1

P&ID JI-191-PR-12-2920-10001-1+2
JI-191-PR-12-2920-10002-1
JI-191-PR-12-2920-10005-1
JI-191-PR-12-2920-10006-1

The purpose of the Closed drain system in GTP-Jihar is to collect hydrocarbon liquids from non-
operating equipment prior to opening for maintenance.
A Closed drain drum V-2921 is buried below the grade level where liquid from GTP equipment can be
drain by gravity through hard piping when this equipment’s require maintenance. The equipment is
drained after isolated, depressurized. During normal operation, the main drains are positively isolated.
The liquid is pumped from closed drain drum only by vacuum truck pump, the Drain Pump P2921A/S
will be isolated.

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

4- Chemical injection demulsifier


PFD JI-191-PR-11-2880-10002-1

P&ID JI-191-PR-12-2880-10003-1

The Demulsifier Injection Unit X-2890 in GTP Jihar consists of one Demulsifier Storage Vessel V-2891
and 2 X 100% Duplex-head reciprocating pump (dual diaphragm with diaphragm rupture detection
device) P-2891A/B.
The Demulsifier package will be rehabilitated and connection point will review during details
engineering design.

5- Chemical injection Methanol


PFD JI-191-PR-11-2880-10001-1

P&ID JI-191-PR-12-2880-10001-1+2+3+4
JI-191-PR-12-2880-10005-1

The Methanol Injection Unit X-2881 in GTP-Jihar consists of one Methanol StorageVessel V-2882 and
2 X 100% Simplex Injection Pumps P-2881A/B.
Methanol is pumped from Methanol Storage Tank TK-2881A/B using Methanol FillingPump P-2882 to
Methanol Storage Vessel V-2882.
Methanol pumped by P-2881A/B is injected on all 4 wellhead flowlines at theinlet of choke valve at
Jihar-2, 6, 8 & Jazal-1 well during start-up to avoid hydrateformation and to prevent/remove any hydrate
formation during plant operation, plant depressurization and upset conditions.

6- Chemical injection CI
PFD JI-191-PR-11-2880-10002-1

P&ID JI-191-PR-12-2880-10002-1

The Corrosion Inhibitor Injection Unit X-2885 in GTP Jihar consists of one Corrosion Inhibitor
Injection Storage Vessel V-2885 and 2 X 100% multi-head reciprocating pumpP-2885A/B.
The corrosion inhibitor is injected continuously on all 4 wellhead flowlines [Jihar 2, 6, 8 &Jazal 1],
before choke valve

7- Hot oil system


PFD JI-191-PR-11-2700-10001-1

P&ID JI-191-PR-12-2700-100 01-1


JI-191-PR-12-2700-100 02-1+2
JI-191-PR-12-2700-100 03-1

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

JI-191-PR-12-2700-100 07-1+2
JI-191-PR-12-2700-100 08-1
JI-191-PR-12-2700-100 01-1

The hot oil system consists of Hot Oil Drain Pump (P-2702), Hot OilProcess Drain Drum (V-2703),
Hot Oil Utility Drain Drum (V-2701), Hot Oil Makeup/Drain Pump (P-2701), Hot Oil Filters (F-2701
A/B), Hot Oil Expansion Drum (V-2702), Hot Oil Heater (H-2701), Hot Oil Run Down Cooler (A-
2701), fired heater (H-2701).
The system is used as a heating medium for Dehydration Inlet Heater (E-2402), And Regeneration Gas
Heater (E-2403)
The Hot Oil System is a closed circuit heating system, the oil will be heated by fired heater (H-2701).
The circulation of hot oil will be through new hot oil pumps, the specification of pumps will be defined
during details engineering design.
Note: the technical specification of hot oil will be submitted by HPC during details engineering, HPC
will supply hot oil in a sufficient QTY for cleaning, testing and operation.

8- Diesel generator
PFD JI-191-PR-11-2960-10001-1

P&ID JI-191-PR-12-2960-10001-1
JI-191-PR-12-2960-10002-1

The Diesel Tank TK-2961 working volume is 40 m³ and is sized to hold sufficient diesel for 2 weeks
operation ( this period will be reviewed regarding to the rated power of new diesel generators) of
Emergency diesel generator.

Diesel Oil Pumps P-2961A/B are used for both tanker unloading operation and transfer to user.
The users of Diesel Fuel are:
1. Emergency Diesel generator Package-GTP (capacity will be define in engineering phase).
2. Emergency Diesel Generator Package-GTP (capacity will be define in engineering phase).
3. Diesel Operated Fire Water Main Pump P-2902A (out of scope).

9- The Instrument air


PFD JI-191-PR-11-2870-10001-1

P&ID JI-191-PR-12-2870-10001-1
JI-191-PR-12-2870-10002-1
JI-191-PR-12-2870-10003-1
JI-191-PR-12-2870-10004-1
JI-191-PR-12-2870-10005-1+2+3+4+5

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

The two Instrument air skid will be installed, the technical specification and capacity will be define
during details engineering study , the skid will be consist of air cooled oil flooded screw compressors
each compressor is designed for air capacity not less than 200 m3/hr including regeneration air quantity
for Dryer.
This section will be more details after complete details engineering design

10- Gas metering skid, GTP


A Sales Gas Metering Skid X-2590 has been provided for gas fiscal metering before theinlet to the
transport pipeline.

Allinstrumentation signals are hardwired from metering skid to UCP-2500,all these signals are wired
serially to new PLC controlsystem.

11- Gas metering skid , stage -2


A Sales Gas Metering Skid X-1221 has been provided for gas fiscal metering before the inlet to the
transport pipeline. The outlet line has a tie-in provision with Sales gas from GTP.
All instrumentation signals are hardwired from metering skid to UCP, all these signals will be wired to
control system of stage -2 when the rehabilitation of stage -2 is completed (instrument air, power supply
and control system). That is not part of scope of work.

Control System (Instrument)


The following systems will be installed at GTP-Jihar:

 Process Monitoring and Control. (Redundant system)


 Emergency Shutdown System (ESD). (Stand-alone)
 Fire and Gas System (FGS) for Fire Protection. (Stand-alone)
 Interface to third party systems(Hot oil system, gas metering unit)
 Monitoring System (PLC.s, Laptops)

The new system will be microprocessor based electrical distributed control system (PLC) for process
monitoring and control and PLC stand alone for ESD and PLC stand-alone for F&G.
The process control system and safety systems (ESD&FGS) will communicate with each other.

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net
ASAS Contracting Ltd.

The main package units hot oil heater & gas metering unit will be controlled by local (PLC) and will be
connected to central PLC.
The emergency system and F&G system will protect the equipment and people with same manner of old
system.

NOTE:

The above-mentioned process has been built according to CFP requirement and taking into
account of remaining facilities in good condition or that could be repaired.

In the event of a contract being awarded to ASAS, it will provide several solutions (Including
requirements reflected to these solutions) to improve the gas conditions to sales export pipeline.

P .O. Box: 678 Tel: + 963 11 2148591


Damascus - Syria Fax: + 963 11 2148590
Email: exe.secretary@asascontracting.net