F30. Ulf-Pf-F06-0001-04-Js1137-Mec

04 07-02-22 Final Issue FOB MRO DMO
03 30-11-21 Re-Issued For Approval FOB MRO DMO

02 20-09-21 Issued For Approval FOB MRO DMO
01 30-06-21 Issued For Review FOB MRO DMO
REV DATE DESCRIPTION PREPARED CHECKED APPROVED
MEC Project #: 81007

CC ENERGY DEVELOPMENT S.A.L
(Oman Branch)
PROJECT
FEED Block 3 and 4 Gas to Power Project
TITLE
OPERATING, CONTROL AND SAFEGUARDING PHILOSOPHY-ULFA

JOB NR. DOCUMENT NR. REV. DATE SHEET
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(Oman Branch) FEED Block 3 and 4 Gas to
Power Project

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Table of Content
ABBREVIATIONS ......................................................................................................................................... 5
HOLD LIST ......................................................................................................................................... 6
1. Objective of Document ................................................................................................................... 7
2. INTRODUCTION ............................................................................................................................... 7
2.1 Existing Facilities ............................................................................................................................. 7
2.1.1 Ulfa EPF ......................................................................................................................................... 8
2.1.2 SHB EPF ......................................................................................................................................... 8
2.2 Project Background ......................................................................................................................... 9
2.3 Project Location ............................................................................................................................ 10
2.4 Project Scope ................................................................................................................................ 10
3. PROCESS DESCRIPTION ................................................................................................................. 12
4. OPERATING PHILOSOPHY.............................................................................................................. 15
4.1 Gas Cooler, 903-HA-01 A/B/C , ..................................................................................................... 15
4.2 Fuel Gas Scrubber, 903-VS-01 AB/C .............................................................................................. 16
4.3 Gas Filter Coalescer, 903-FR-01 A/B/C,......................................................................................... 17
4.4 Electric Heaters, 903-EH-01 A/B/C................................................................................................ 18
5. CONTROL PHILOSOPHY ................................................................................................................. 20
5.1 Gas Cooler, 903-HA-01 A/B/C ....................................................................................................... 20
5.2 Fuel Gas Scrubber, 903-VS-01 A/B/C ............................................................................................ 20
5.3 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C .................................................................................. 20
5.4 Fuel Gas Heater, 903-EH-01 A/B/C, .............................................................................................. 20
5.5 Pressure Regulators, ..................................................................................................................... 21
6. SAFEGUARDING PHILOSOPHY ....................................................................................................... 21
6.1 High High Pressure Protection of the System ............................................................................... 21
6.2 High High Temperature Protection of the System ........................................................................ 22
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6.3 Low Low Temperature Protection of the System ......................................................................... 22
6.4 Gas Cooler, 903-HA-01 A/B/C, ...................................................................................................... 22
6.5 Fuel Gas Scrubber, 903-VS-01 A/B/C, ........................................................................................... 23
6.6 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C, ................................................................................. 23
6.7 Fuel Gas Heater, 903-EH-01 A/B/C, .............................................................................................. 23
6.8 Fire and Gas Detection Safeguarding............................................................................................ 24
7. Vent and Depressurization Philosophy ......................................................................................... 26
8. Start-up & Shutdown Philosophy.................................................................................................. 26
9. Purging Philosophy........................................................................................................................ 28
10. Isolation Philosophy ...................................................................................................................... 29
11. MAINTENANCE Philosophy ........................................................................................................... 29
12. Manning Philosophy ..................................................................................................................... 29
13. Draining philosophy ...................................................................................................................... 29
14. SAMPLING philosophy .................................................................................................................. 29
15. Sparing Philosophy ........................................................................................................................ 30
16. References .................................................................................................................................... 31
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ABBREVIATIONS
EPC - Engineering Procurement Construction
MEC - Muscat Engineering Consultancy LLC
PO - Purchase Order
RFQ - Request for Quotation
SOW - Scope of Work
EPF - Early Production Facility
SDV - Shut down Valve/ on/off valve
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HOLD LIST
HOLD-1- Fuel Gas Cooler Process Data to be finalized based final Gas Engine Vendor
requirement on gas specification
HOLD-2- Fuel Gas Heater Process Data to be finalized based final Gas Engine Vendor
requirement on gas specification
HOLD-3- Chiller package details to be finalized during detail design by Chilled water package
Vendor.
HOLD-4- Pressure Regulating Valves Process Data inside Gas engine package
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1. OBJECTIVE OF DOCUMENT
The purpose of this document is to define the operating, control and safeguarding philosophy
for the new Gas Conditioning Facility to provide the gas to the new gas engines in the ULFA
plant. This document covers the unit required for conditioning of the fuel gas to send to gas
engine package. The details of the Gas Engine operating, control and safeguarding philosophy
shall be referred to the final selected vendor document. For all philosophies related to the
power management system refer to the “Power Generation & Distribution Philosophy”
prepared under this project scope of work with document number: COM-XX-G04-2006-001.
2. INTRODUCTION
CCED is the Operator of Blocks 3 & 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 produced fluids at FARHA, SAIWAN, SHB and SHF
and ULFA facilities.
Separated oil from all the other stations transported to SAIWAN storage facilities. From
SAIWAN, crude is transported to CCED’s custody metering at Qarn Alam via an 83 km 16” oil
pipeline and then to the PDO Main Pipeline System.
2.1 Existing Facilities

Figure3.1 shows Block 3 and 4 facilities layout. Block 3 comprises the Farha, and Ulfa station
and Block 4 comprises the SHB, SHF and Saiwan Station.
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Figure 3.1: Overall Schematic of Existing Facilities
2.1.1 Ulfa EPF

The ULFA EPF receives fluids from the SAMHA, ULFA and FARHA RM-10 wells. Ulfa EPF will
also receive fluids from the Masarrah wells when needed. The well fluids are treated in the
separation train. The separated oil is routed heater treater then to the crude oil storage
tanks and finally to Saiwan via the Ulfa-Saiwan 8” piggable pipeline by the crude oil booster
and transfer pumps. The produced water is processed to meet subsurface specifications
and routed to the water injection wells. Gas liberated in the separation stage (separator
and heater treater) is utilised as fuel gas and excess gas will be flared. Power is generated
at the facility using diesel generators. As part of this project, power will be generated at
Ulfa Power facilities and exported to Ulfa EPF and wells.
2.1.2 SHB EPF

The SH-B, SH-D gross fluids are processed in four parallel separators followed by one heater
treater. The processed oil is then routed to the Oil Storage Tank. Oil is routed to the Saiwan
Station via the 12” piggable line for export. The produced water is processed to meet
subsurface specifications and routed to the water injection wells. Gas liberated in the
separation stage (separator and heater treater) is utilised as fuel gas and excess gas will be
flared. Power is generated at the facility using diesel generators. As part of this project,
power will be generated at SHB power facilities and exported to SHB EPF and wells.
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2.2 Project Background

Currently, fuel gas used to fire heater treaters at all stations, but the majority of associated
gas is flared. Power generation in the field provided via diesel generator sets. The ULFA
facility produces and flares most of the gas in these Blocks. CCED recognizes the
opportunity to create value through the utilization of this associated gas.
Within project early stage design and concept selected project will proceed with two power
plant and associated OHL power distribution one for block-3 and the other one for block-
4. The power plant for block-3 located at the vicinity of ULFA station and for block-4
adjacent to existing SHB EPF.
Fuel gas for power plant supplied from associated gas collected in each EPF. Generated
power distributed to the consumers via 33kV OHL based on concrete poles.
Expected start-up date is Q4 2023 but it is a project aspiration to start up as soon as

possible.
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2.3 Project Location

The proposed facilities will be located with Block-3 & 4 as shown in Figure 3.2
Figure 3.2: Project Location
2.4 Project Scope

The Project comprise of completely two independent power plants and associated power
distribution networks based on Concrete pole OHL. Power plant at block-3 will be located
at the vicinity of ULFA EPF. Stepped up 33kV Voltage then feed OHL grid started from power
plant location covering all block-3, feeding all the Wells, stations, camps and other facilities.
OHL coverage shall be maximum to keep the diesel power generation as low as reasonably
practicable. Power plant at block-4 will be located adjacent to SHB EPF where maximum
associated gas is available and OHL grid feed all the loads in block-4 as mentioned above.
Prime mover for power generation units shall be gas engines suitably chosen based on
Project specifications such as location, ambient conditions, gas composition, etc. Fuel gas
for the power plants shall be supplied from existing ULFA and SHB stations. Forecast of Gas
production profile of these stations shall be reviewed against the estimated fuel gas
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requirements calculated during the FEED. Existing stations shall be modified as required to
provide suitable fuel gas to the power plants. Each power plant shall comprise of suitably
designed black starting means and sufficient backup power generation to feed power to
EPF and sufficient number of high gas producing wells in order to reinstate all operations
in case of field total shutdowns lead to power black-out due to shortage of fuel gas. OHL
preliminary routing for each block is prepared based on GIS data. Route survey and relevant
studies are part of the scope of this Contract. Refer to the Figure 3.3 for the overall
schematic of the project.
Figure 3.3: Project Scope Schematic
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3. PROCESS DESCRIPTION
The process description given below shall be read in conjunction with PFD and P&ID (latest
revision) of gas to power project in ULFA plant.
The existing gas header to flare and the existing fuel gas system is designed for 9 MMSCFD.
The fuel gas conditioning unit is designed with skid mounted for 3 MMSCFD per skid to
provide the fuel gas to the gas power units which involves gas engine generators trains in
3 skids (2 working + 1 standby).
As per estimations received from different gas engine vendors at FEED stage, total amount
of 4 MMSCFD fuel gas will be sufficient for the total about 13.36 MW power demand
produced in about 11 set of gas engine generators.
The required design capacity of the 3 MMSCFD in Ulfa is provided with 3 fuel gas
conditioning skids each of them with 3 MMSCFD capacity. In normal operating condition
all 3 skids will be in service. In case of any process trips and maintenance requirement
which required one skid to be out of service two other skids is designed to meet the total
gas required.
However, in the future when the gas forecast is there is possibility to relocate one fuel gas
conditioning skid as well as required gas engines from SHB station to the Ulfa. In this
scenario total installed fuel gas skid in Ulfa will be 4 skids (3 working +1 standby) which is
sufficient to provide 9 MMSCFD gas to power plant gas engines with total demand of 32.83
MW.
In the following process description and safeguarding and control philosophies all tag
numbers ended with A is indicated for the Skid A and will be the same for skids B and C
with letters B and C respectively.
The fuel gas inlet line will be tapped the existing gas header before entering to the existing
fuel gas drum (423-CM-001) at 3 barg.
The connection to the other skids is taken from upstream of the skid A inlet UZV’s.
The fuel gas is entering the fuel gas conditioning skid A via inlet UZV’s (903-SDV-001/002
A/B/C).
Then will enter to the Gas Cooler (903-HA-01 A/B/C) (HOLD-1).
The Gas Cooler will cool down the fuel gas temperature to a level around 20°C in case of
high temperature conditions in summer case. This will be done through a shell and tube
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heat exchanger. The chilled water will be used as coolant from chilled water package (903-
XX-01 A/B/C) (HOLD-3). The minimum temperature of the chilled water is available at
chiller package is considered as 10°C. The Gas Cooler will not be in operation in the case of
winter case fuel gas temperatures from the header which is around 7-10°C.
The Fuel Gas Scrubber, 903-VS-01 A/B/C, is designed to remove any liquid droplets equal
to and larger than 10 microns. The separator is equipped with wired mesh demister pad.
The liquid from the scrubber is sent to the existing flare header via 903-UV-003 A/B/C.
Then Fuel gas will pass to the Gas Filter Coalescer, 903-FR-01 A/B/C. By going through the
cartridges from outside to inside any solid particles equal to and larger than 1 micron and
liquid droplet equal and larger than 3 micron will be separated from the stream which is
going the Gas Engines.
The liquid from the filter coalescer is sent to the existing flare header via 903-UV-004
A/B/C.
The gas from filter coalescer enters the electric heater, 903-EH-01 A/B/C for heating the
gas such that the fuel gas temperature is maintained at minimum margin of around 10°C
(HOLD-2) above the HC dew point temperature and water dew point temperature,
whichever is the highest at the Engine battery limit.
The gas coming from all 3 fuel gas skids after heaters will collect in common header and
then send to the Gas Engine package
Fuel gas flowmeter, 903-FIRQ-001, is provided to measure the total flow rate going to the
power plant.
Connection for online gas chromatograph, 903-GC-01, is provided downstream of flow

meter to analyse the gas composition and calculate the LHV, and GHV and dew point of
the gas sending to the power plant.
The fuel gas then will pass through the pressure regulator trains installed separately at
each engine inlet, to adjust the pressure for the inlet to the Gas Engines as per final vendor
requirements. The pressure regulators trains is considered inside the Gas Engine
Generators vendor package since it is final element before entering to the gas engine and
requires specific design parameter based on the Gas Engine operating envelope.
The relief valves and the manual vents and de-pressurizing lines inside fuel gas skids will
be connected to the existing LP flare system via a common header.
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A new maintenance drain collection header from, Gas Cooler, Gas Scrubber, Gas Filter
Coalescer and Gas Heater will be sent to new drain collection pit ,903-VS-02 from all skids.
Draining shall be done manually from Gas Cooler, Gas Scrubber, Gas Filter Coalescer and
Gas Heater after depressuring of the equipment. Level gauge is provided on drain pit for
level indication. The drain pit (903-VS-02) will evacuate by vacuum truck via provided
connection.
Instrument air for the Fuel Gas Conditioning Unit will be provided from new dedicated
instrument air package (903-XX-05) considered for power plant project scope.
Utility water supply is required for make-up water for the chilled water system. This can be
supplied by truck since the chiller package (HOLD-3), 903-XX-01 A/B/C will have the
required storage tank for the chilled water circulation. The amount and quality of the
makeup water will be finalized during Detail Design stage after final Vendor data.
Make up water supply is required for each gas engine also. The amount and quality of the
makeup water will be finalized during Detail Design stage after final Vendor data.
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4. OPERATING PHILOSOPHY
This section highlights the operating philosophy for the Gas Conditioning Unit to send the
gas to the Gas Engines. For the gas engine generators, the vendor operating, and
maintenance manual shall be followed. The new facilities shall be manned and fully
designed to be operated remotely and started in fully automatic mode from control room as
well as locally (in case of any requirement).
Since the fuel gas conditioning unit is designed based on skid mounted philosophy to have
3 fuel gas skids in parallel, the following description is for the Skids A, B and C. In normal
operation, all 3 skids will be in the operation. However, the capacity of two skids together
shall be sufficient to provide the required gas to the Gas Engines in case of one skid is under
maintenance. For the same reason each skid capacity is selected for 3 MMSCFD.
However, in the future when the gas forecast is there is possibility to relocate one fuel gas
conditioning skid as well as required gas engines from SHB station to the Ulfa. In this
scenario total installed fuel gas skid in Ulfa will be 4 skids (3 working +1 standby) which is
sufficient to provide 9 MMSCFD gas to power plant gas engines with total demand of 32.83
MW
4.1 Gas Cooler, 903-HA-01 A/B/C

The gas cooler is provided to cool down the fuel gas temperature to the level of around
20° C. This will ensure to drop out some water and heavy components in the fuel gas line
especially in summer case when temperature in the inlet fuel gas is around 52°C.
Based on the received vendor requirements the fuel gas temperature at the inlet to gas
engine package shall a margin of around 10 °C above the hydrocarbon dew point or water
dew point whichever is higher. On the other hand, the maximum recommended
temperature of the fuel gas to the gas engines is around 50°C (some vendors
recommended around 35° C while the others recommend up to 55°C).
To meet both above requirement two modes of operations foreseen:
1- Winter Case (Fuel gas inlet temperature is around 10° C): since the gas is coming from
the production separators it shall be considered as saturated gas. It means the
Hydrocarbon/Water dew point will be around the same stream temperature. In this
case the cooler will NOT be in service, but the electric heater is required to be in service
to make a required margin on top of hydrocarbon and water dew points. The
temperature of 30°C is recommended to have at heater outlet in this case.
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2- Summer Case (Fuel gas inlet temperature is around 52°C): since the gas is coming from
the production separators it shall be considered as saturated gas. It means the
Hydrocarbon/Water dew point will be around the same stream temperature. In this
case the cooler will be in service. If Gas Cooler is not in service in this case to meet the
margin required for fuel gas temperature above dew point the Gas Heater shall heat
up the gas to above 62°C which is not meeting the maximum recommended values for
the Fuel Gas Temperatures to the Gas Engines. Therefore, gas cooler at first should
cool down the fuel gas temperatures to a level of 20°C then electric heater is required
to be in service to make a required margin on top of hydrocarbon and water dew
points. The temperature of 30 °C is recommended to have at heater outlet in this case.
The operating and design conditions of this separator are summarized as below:
Table 1: Gas Cooler, 903-HA-01 A/B/C
Parameter Value
Design Capacity , Fuel Gas Side 3 MMSCFD
Design Capacity , Chilled Water Side 16.5 m3/hr
Operating Pressure Fuel Gas Side (Min / Max) 2 /3 bar (g)
Operating Pressure Chilled Water Side 3/4 bar (g)
Operating Temperature Fuel Gas Side (Min / Max) Inlet 7.4 to 52 °C

Outlet: 7.4 to 20 °C
Operating Temperature Chilled Water Side (Min / Max) 10 to 15 °C
Design pressure, , both Side 9 bar g
Design temperature (Min / Max), both side 0 °C / 82 °C
Allowable maximum differential pressure Shell 0.2 bar (water)
Tube 0.3 bar (gas)
4.2 Fuel Gas Scrubber, 903-VS-01 AB/C

The Fuel Gas Scrubber is provided with high differential pressure alarm 903-PDIA-003A/B/C
across the demister pad to alert the operator. The Fuel Gas Scrubber demister pad element
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are clogged shall be first completely depressurised and drained and shall be cleaned. The
frequency of the clogging demister pad is very low.
In addition, Low alarm on 903-PI-002A on gas outlet of scrubber 903-VS-01A/B/C is

provided.
Table 2: Gas Scrubber, 903-VS-01 A/B/C
Parameter Value
Design Capacity , 3 MMSCFD
Operating Pressure, (Min / Max) 2 /3 bar (g)
Operating Temperature, (Min / Max) 7.4 / 20 °C
Design pressure, 9 barg / FV
Design temperature (Min / Max) 0 °C / 82 °C
Allowable differential pressure 0.2 bar
Liquid separation efficiency Minimum guaranteed liquid particle

removal is 100% for ≥ 10 microns
4.3 Gas Filter Coalescer, 903-FR-01 A/B/C,

The Fuel Gas Filter Coalescer is provided with high differential pressure alarm 903-PDIA-
004A/B/C across the filter to alert the operator. The operating and design conditions of the
Gas Filter Coalescer is summarized as below:
Table 4: Gas Filter Coalescer, 903-FR-01 A/B/C
Parameter Value
Design Capacity, 3 MMSCFD
Operating Pressure, (Min / Max) 2 /3 bar (g)
Operating Temperature, (Min / Max) 7.4 / 20 °C
Design pressure, 9 barg / FV
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Parameter Value
Design temperature (Min / Max) 0 °C / 82 °C
Allowable differential pressure 0.1 bar
Solids at filter inlet 0.5-50-micron,
Solids at filter outlet Minimum guaranteed solid particle

removal is 100% for ≥ 1 microns
And 100 % liquid droplet ≥ 3 microns
Note: to be confirmed by gas engine

vendor during EPC
One check valve is provided at the discharge line of each skid to prevent back flow from
the other skids and to read the correct pressure value through the pressure transmitters
in-side each skid.
4.4 Electric Heaters, 903-EH-01 A/B/C

The gas from the filter coalescer enters the electric heater, 903-EH-01 A/B/C for heating
the gas such that the fuel gas temperature is maintained at minimum around 10°C (HOLD-
2) at the Gas engine battery limit above the HC dew point temperature and water dew
point temperature, whichever is the highest.
During normal operation one Electric Heater will be in operation
Two modes of operation of foreseen in Gas Cooler section above is also applicable here for
heater also. Unlike cooler, heater operation is required in both winter and summer most
of the time.
Heater maintenance shall be done by manual change over between skids.
A pressure gauge and temperature transmitter is provided on heater inlet line and outlet
line for local indication and indication in control system.
Heater shell shall be completely depressurised and purged before carrying out any
maintenance on heater package.
The operating and design conditions of the Electric Heater can be summarized as below:
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Table 5: Electric Gas Heater, 903-EH-01 A/B/C, (HOLD-2)
Parameter Value
Design Capacity , 3 MMSCFD
Design Heat Duty 42 kW
Operating Pressure 1.5/2.5 bar (g)
Operating Temperature (Inlet / Outlet) 6.5 to 20 °C / 30 °C
Design pressure 9 bar (g) / FV
Design temperature (Min / Max) 0 / 100 °C
Detailed operating philosophy of heater package shall be provided by Vendor.
In addition, flow transmitter, 903-FT-002A, for each fuel gas conditioning unit is provided
and configured with low alarm to DCS.
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5. CONTROL PHILOSOPHY
5.1 Gas Cooler, 903-HA-01 A/B/C
Temperature controller, 903-TICA-002 A/B/C, with high alarm is provided at Fuel Gas line
outlet of the cooler to control of the outlet temperature in the summer case at 25° C by
sending signal to Chiller package to turn on the circulation pump the chilled water supply
line. The controller will send turn on signal to duty chiller package if the gas temperature
is 25° C and turn off signal on 20° C.
5.2 Fuel Gas Scrubber, 903-VS-01 A/B/C

Level gap controller, 903-LICA-003 A/B/C, is provided at Fuel Gas Scrubber to control of the
level of the scrubber by sending signal on/off valve, 903-UV-003 A/B/C.
5.3 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C

Level gap controller, 903-LICA-004 A/B/C, is provided at Fuel Gas Scrubber to control of the
level of the scrubber by sending signal on/off valve, 903-UV-004 A/B/C.
High alarm 903-DPIT-004 A/B/C is provided for monitoring the differential pressure across
the filter elements.
5.4 Fuel Gas Heater, 903-EH-01 A/B/C,

The Electric Heaters packages are provided with thyristor control panel to control the heat
input to gas and is designed such that the fuel gas temperature is maintained at required
temperature of 30°C.
High and low temperature alarms, 903-TIA-004 A/B/C H and L, (55°C and 20°C).
The temperature controller, 903-TICA-004 A/B/C, with high alarm, is located at the outlet
of Fuel Gas Heater. This controller controls the temperature by sending signal to thyristor
control panel inside heater vendor package.
The set point of the temperature controller, 903-TICA-004 A/B/C, is 30 °C, which has been
decided based on the increasing temperature above inlet to heater and the operating
pressure at the inlet to the Gas Engine. Low temperature alarm (set at 20 °C) is also
provided on the temperature controller to alert operator that gas temperature is reaching
the dew point condition. Moreover, the operator can change the set point at any time
during operation based on different gas composition in summer or winter.
Detailed control philosophy of heater package shall be provided by Vendor.
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In addition, new flow transmitter with low alarm, 903-FT-002 A/B/C, is provided in the
outlet line of heater and connected to DCS.
5.5 Pressure Regulators,

Pressure regulator s is considered to reduce the pressure to around 0.3 to 0.5 barg to send
to the engine inlet. The Pressure Regulators is considered inside the engine package since
the final exact value of set point required for each engine can be adjusted by vendor
instruction itself. (HOLD - 4)
A mean value of the 3-pressure transmitter reading, 903-PIT-006/007/008, are provided

and shall be sent to the power management system to stop individual engines in case of
the low pressure in the fuel gas header.
6. SAFEGUARDING PHILOSOPHY
6.1 High High Pressure Protection of the System
Since design pressure of the upstream system of the fuel gas system is 47.5 barg in
production separators at the inlet of the Gas Conditioning Unit 2oo3 pressure transmitters
are considered to act as high high pressure protection of whole skid. The set point of the,
903-PZITHH-001/009/010 A/B/C transmitters will be considered as 8 barg which is 1 bar
lower than system design pressure of 9 barg. This Pressure transmitters will close IPF
valves, 903-SDV-001/002 A/B/C at inlet of each skid. The basis of the selecting of this design
pressure and IPF valve are:
- Design pressure of the upstream system of the fuel gas header is 47.5 barg at
production separators while the PZAHH set points on the same separators are
somewhere about 18 barg and PCV’s on production separators vapour outlet lines
discharging to the fuel gas header are set at 5 to 7 barg.
- Existing RV’s on the existing fuel gas KOD set at 8 barg. The tie-in for the new fuel gas
conditioning unit is taken upstream of the existing Fuel gas KOD.
- If new IPF valves, 903-SDV-001/002 A/B/C, which sets at 8 barg, for all pressure relief
valves inside the fuel conditioning gas unit are not provided then all relief valves inside
the fuel gas skid shall be evaluated for the PCV’s failure case from upstream production
separators with maximum operating pressure of 18 barg at upstream of the PCV’s
located on production separators. This will cause higher relief load to the flair and
hydrocarbon loss.
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- Design pressure inside fuel gas conditioning unit is selected 9 barg (1 bar margin on
top of the IPF valves set point) to have flexibility in case of lower maximum allowable
pressures values requirement at inlet to the pressure regulators by other GE vendors
no need to re-evaluate again all pressure relief valves inside fuel gas conditioning unit.
- Refer to the design review discussion and action number No. 9 at FEED stage it is
decided finally to have IPF valves at inlet of each skid having set pressure of 8 barg as
well as design pressure of the 9 barg for the fuel gas conditioning skid.
- Refer to the FEED stage HAZOP action N1-1 There is one PSV on existing FG header.
423-PSV-002, with set point of 8 barg; Therefore, it is decided to add new PSV, 903-
PSV-004, as standby for the existing PSV. keeping set point of new PSV-(903-PSV-004 )
on the FG header on 17.5 barg will not eliminate the hazard for the existing FG
downstream system which is designed for the 8 barg , 423-PSV-002, on the existing FG
header, because of the limitation of the existing flare header for the upstream PCV
failure scenario from production separators. Hence It is decided to do the separate
HAZOP review meeting out of the current project scope to evaluate the potential
hazards on FG existing system from upstream high pressure production separators.
Considering the existing flare package capacity limitation.
6.2 High High Temperature Protection of the System

Since the maximum operating temperature of the upstream system of the fuel gas system
is around 60 °C and the selected design temperature of the fuel gas conditioning system is
82°C therefore no need for the high high temperature protection at the inlet of gas
conditioning unit.
6.3 Low Low Temperature Protection of the System

Since the operating pressure of the whole Fuel Gas Conditioning unit is low as 2 to 3 barg
and minimum operating temperature is around 6 to 9 °C, it is not expected to have extreme
low temperature cases during depressurization and pressurization (Refer to vent and blow
down and depressurization study report under this project scope). Therefore, the
minimum design temperature of the equipment selected as 0°C is inherent against
protection for low low temperature.
6.4 Gas Cooler, 903-HA-01 A/B/C,

Entire skid is protected by IPF valves 903-SDV-001/002 A/B/C set at 8 barg and equipment
are designed for 9 barg and hence no need for additional protection. However, safety relief
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valve is considered for the fire case in this equipment. Design conditions are established
not just based on operating conditions but upset conditions also.
The cooler is linked with plant safeguarding chiller trip on inlet PZAHH and plant ESD.
6.5 Fuel Gas Scrubber, 903-VS-01 A/B/C,

Entire skid is protected by IPF valves set at 8 barg and equipment are designed for 9 barg
and hence, no need additional protection. However, safety relief valve is considered for
the fire case in this equipment.
6.6 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C,

and hence no additional overpressure protection is required for equipment with FG skid,
however PSV is provided on equipment for fire case only. Therefore, no need additional
protection. However, safety relief valve is considered for the fire case in this equipment.
High ala rm 903-PDIA-004 A/B/C is provided for monitoring the differential pressure across
the filter elements.
High high level protection, 903-LZIT-005 A/B/C, is provided to protect the downstream
equipment as well as the gas engines by closing inlet ESD valves, 903- SDV-001/002 A/B/C,
to prevent sending liquid to the gas engines. This type of safeguarding shall be finalized
after final selected vendor requirement and tolerance on liquid receiving in the fuel gas in
upset condition.
6.7 Fuel Gas Heater, 903-EH-01 A/B/C,

and hence no additional overpressure protection is required for equipment with FG skid,
however PSV is provided on equipment for fire case only.
Following safeguards shall be finalized by Vendor.
• High-high element temperature, 903-TIZA-005 A/B/C _HH

• High-high flange temperature, 903-TIZA-006 A/B /C_HH
• High-high gas outlet temperature,903- TIZA-007 A/B/C _HH
• Manual ESD, 903- HZA-001 A/B/C
• Plant ESD Shutdown,
Safeguarding logic for package shall be implemented in plant safeguarding system and
vendor shall provide required signal to/from package. Number of transmitter (initiators)
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required for package safeguarding shall be decided by Vendor According to SIL assessment
and SIL verification.
After a process trip, the heater should be able to be reset from Field / Heater Local Control
Panel and Control Room (DCS).
High-high gas temperature. 903-TZA-007 A/B/C in vendor package trip set point shall be
set at 50 °C to not send the high temperature gas to the engines which will trip the duty
heater (HOLD-2).
Heater ESD Push Button is also provided for Emergency trip along with ESD reset.
6.8 Fire and Gas Detection Safeguarding

The Fire and gas detection system will be provided for entire facilities in accordance with
international standards the FGS system will be integrated over the network with DCS
system.
The Fire and Gas Detection system is designed to provide an effective early warning of a
fire or gas event in process facilities and buildings.
The following Fire & Gas detectors/devices considered for new facilities:
• Open path/line of sight (LOS) infra-red flammable gas detector;
• Infrared hydrocarbon gas detectors (point type);
• Triple IR flame detectors;
• Optical type smoke detectors for fire detection within buildings;
• Hydrogen (H2) detectors for battery room;
• Manual Alarm Call (MAC) point for manual activation;
• Siren; Beacon;
• Fire Bell.
F&G mapping study is conducted to identify the quantity fire and gas detectors in the field.
H2S detector will be provided throughout the facility as per F&G Philosophy.
As per Fire, Gas Dispersion, and Explosion Assessment results, proposed separation
distance between each gas conditioning units (31 m) adequate (i.e. radiation exposure is
below 37.5 kw/m2) to avoid escalation between one gas conditioning unit to the other.
Fire duration assessment has been calculated to less than 5 minutes assuming each gas
condition unit can be separately isolated. Therefore, Isolating each gas inventory is
beneficial:
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- to limit the inventory and consequently the fire event duration.
- to ensure the availability of the system – i.e. the other two gas conditioning units can be
operated.
As pe above the shutdown valves, 903-SDV-005 A/B/C are considered at each skid outlet
also.
Activation smoke alarm in the building will automatically initiate an alarm, raised through
the FACP, displayed on the DCS HMI shall initiate the alarm and trip of AC unit. Smoke
detection in building shall trip the HVAC.
Refer to FEED design review action no. 15 each fuel gas conditioning skids are considered
separate fire zones. Confirmed fire detection from each skid will close the same skid inlet
ESD valves not the other skids. Also separate ESD (solenoid shut off valve to be supplied by
vendor as loose item) at each Gas Engine Inlet shall be considered for F&G protection and
segregation of each engine from the other engines.
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7. VENT AND DEPRESSURIZATION PHILOSOPHY

Since the system operating is low no automatic depressurizing is foreseen for the Gas
Conditioning Unit. All venting and depressurizing requirement shall be done through
provided manual valves.
The depressurization shall be carried out after proper shutdown. Depressurization of any
one system/equipment shall be carried out at one time.
The vent line from Gas Cooler, 903-HA-01 A/B/C, Fuel Gas Scrubber, 903-VS-01 A/B/C, Gas
Filter Coalescer, 903-FR-01 A/B/C, Electric Heaters, 903-EH- 01A/B/C and all piping are
connected to the existing Flare header at SHAHD B station. Minimum Slope of 1:500 will
be maintained for the new vent lines.
For the relief valves downstream of the pressure regulators trains since their set pressures
will be very low shall route to the safe location to the atmosphere.
8. START-UP & SHUTDOWN PHILOSOPHY

The two types of start-ups are:
Initial start-up:
It is ensured that the pre-commissioning activities are complete, and the systems have full
mechanical and functional integrity.
The new facility is connected to existing facility and total facility is as per project P&ID’s.
The system is purged with Nitrogen to ensure the system is hydrocarbon gas free.
Start-up pressurisation activity is done to introduce the hydrocarbon gas into the system.
Start-up after shutdown:
After the initial start-up, subsequent starts shall be from a condition wherein the system is
not depressurised and with hydrocarbon inventory; hence purging may not be required.
It shall be ensured that all the utility systems are available, and the system shall be re-
pressurised to stabilize the hydrocarbon gas flow through the system.
The three types of shutdown are:
Planned Shutdown: A planned shutdown may occur for one of the following reasons:
Preventive and periodic maintenance, for modifications.
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Emergency Shutdown: The main cause which is required a Fuel Gas Skid ESD is each skid
fire and gas system which will initiate only that particular skid by closing inlet/outlet shut
down valve. The entire plant ESD in the cause of existing plant IA header pressure low low
and existing flare KOD level high high will not initiate shutdown of the fuel gas conditioning
on direct shutdown signal. Hence no need direct signal from entire existing plant ESD to
new fuel gas conditioning skid.
ESD signal from new dedicated Instrument Air package header low low pressure will cause
all 3 fuel gas conditioning skids.
Operational Shutdown: can be done automatically due to one of the following reasons:
• Fuel gas high high pressure at inlet of the unit (unit process shutdown), 903-PIZA-
001/009/010 A/B/C_HH
• High high heater outlet temperature (Equipment shutdown), 903-TIZA-007
A/B/C_HH
• High high level in the fuel gas filter coalescer (unit process shutdown), 903-LIZA-
005 A/B/C_HH
• New dedicated IA package header low low pressure signal , 903-PIZA-11 A/B/C
(common for all skids)
In case of Power Plant shutdown, production wells go off and consequently no fuel gas will
be available in the station for Power Plant start up. In this situation new emergency diesel
generator package in power plant shall brought to the service. Once the available gas in
header identified as available the normal start up procedure shall be followed for the fuel
gas conditioning unit.
Start-up checks
The below checks have to be carried out before first start-up:
All pre-commissioning activities of the system are carried out.
Before the first start-up
The following conditions shall prevail before the first start-up:
Gas is available up to the 10” isolation valves at the tie-in location.
The vent lines are connected to the existing vent system.
Instrument air lines are connected to instruments from instrument air header.
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Drain header from unit is connected to new drain pit.
Electric heater power connection is as per vendor drawing and documents
Chilled water package is available and connected to the power
All instrument loops are checked
The entire new system is filled with nitrogen
All instruments are mounted in place and tested
Commissioning
The first commissioning is a crucial operation which shall be carried out by specialized
team. Detailed commissioning procedure will be developed by commissioning team.
System Pressurization
The source of Gas for the initial pressurization of Gas Conditioning Unit is from the 8” gas
header from production separators connected to the existing fuel gas system.
Pressurization of individual equipment’s shall be done by opening the main isolation valves.
Start-up after ESD
In case of ESD, all shutdown valves (UZV’s) will close. However, the pressure in the system
will be contained unless the operator decides to depressurize the facilities. After identifying
the cause of ESD and rectifying the problem, the UZV’s are to be reset locally and re-
pressurization of facilities shall follow the same philosophy described as above.
9. PURGING PHILOSOPHY
2” purge connections are provided at the inlet of the Gas Conditioning Unit, Fuel Gas Scrubber
Vessel, Gas Filter Coalescer and Electric Heater.
Nitrogen purging will be done by connecting the existing mobile nitrogen skid to the purge
connections.
Nitrogen purging ensures that all dead pockets are cleared and free from hazardous process
medium. Purging shall be performed prior to handover of the equipment to maintenance
activity. System shall be depressurized, drained and purged with neutral/inert medium for
ensuring inertness.
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10. ISOLATION PHILOSOPHY

The fluid handled is sweet, and pressure rating is 150# therefore the Single Block and Bleed
philosophy is followed in the Gas Conditioning Unit. Required positive isolation means is
provided to ensure the complete isolation of the equipment from whole system during
maintenance.
11. MAINTENANCE PHILOSOPHY
For maintenance of the equipment in fuel gas conditioning unit the equipment shall be isolated,
depressurized and purged with nitrogen. Utility connections are provided on the piping around the
equipment for purging purposes. Manual isolation valves are provided on the each equipment inlet
and outlet lines to provide isolation from upstream and downstream systems in case of any
maintenance. For more details refer to the separate “Operating and Maintenance Philosophy”
prepared under scope of this project with document number: COM-XX-G01-2000-
004_01_JS1137.
12. MANNING PHILOSOPHY

The new facilities shall be manned and operated by the operators available at site. New
operation team will be considered on shift basis presenting in a separate power plant control
room to facilitate the new fuel gas conditioning unit as well as power plant system. For more
details refer to the separate “Operating and Maintenance Philosophy” prepared under scope
of this project with document number: COM-XX-G01-2000-004_01_JS1137.
13. DRAINING PHILOSOPHY

Liquid drain from equipment, Gas Cooler Fuel Gas Scrubber Vessel, Gas Filter Coalescer and
Electric Heater from all fuel gas conditioning skids will be transferred to the new drain pit 903-
VS-02. Process drains from scrubber and Coalescer are routed to the existing LP flare KOD
through a level control(on/off) mechanism. The operator should ensure the system is fully
depressurised before opening any drain valve to avoid gas cloud formation in operating area.
Level Gauge 903-LG-002 is provided on drain pit to monitor during draining and drain pit shall
be regularly emptied out by vacuum trucks.
14. SAMPLING PHILOSOPHY

A new gas chromatograph, 903-GC-01, is provided at downstream of the fuel gas conditioning
unit to show the gas composition and calculate the LHV and GHV of the gas. In addition,
sample point connection is provided at downstream of the gas chromatograph, 903-GC-01.
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15. SPARING PHILOSOPHY

Since the fuel gas conditioning unit is designed based on skid mounted philosophy to have 3
fuel gas skids in parallel. In normal operation all 3 skids (3x33% in operation) will be in the
operation. However, the capacity of two skids together shall be sufficient to provide the
required gas to the Gas Engines in case of one skid is under maintenance and standby (2x50%
Working + 1 Standby). In this design all equipment and valves inside each skid does not have
spare. Instead, if any of the equipment (Gas Cooler, Chiller Package, Gas Scrubber, Gas Filter
Coalescer) and relief valves inside the skid is under maintenance and service that skid will be
isolated and only two other skids will be in service.
Drain pit ,903-VS-02, is considered common without spare for all skids.
Enough spare shall be considered for gas engines considering that there will be numbers of
gas engine cells based on required power demand and final selected vendor arrangement.
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16. REFERENCES
1- FEED Project Design Basis, COM-XX-G04-2005-001_01_JS1137,
2- Project P&ID’s:
- ULF-FL-F02-0007-001-01-JS1137-MEC ULF-FL-F02-0009-001-01-JS1137-MEC,
ULF-PF-F01-2001-001-01-JS1137-MEC, ULF-PF-F01-2002-001-01-JS1137-MEC,
ULF-UF-F02-0014-001-01-JS1137-MEC
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04 07-02-22 Final Issue FOB MRO DMO

03 30-11-21 Re-Issued For Approval FOB MRO DMO

MEC Project #: 81007

OPERATING, CONTROL AND SAFEGUARDING PHILOSOPHY-ULFA

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SHEET REVISIONS SHEET REVISIONS

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OPERATING, CONTROL AND SAFEGUARDING PHILOSOPHY-ULFA

HOLD LIST ......................................................................................................................................... 6

1. Objective of Document ................................................................................................................... 7

2.1 Existing Facilities ............................................................................................................................. 7

2.1.1 Ulfa EPF ......................................................................................................................................... 8

2.1.2 SHB EPF ......................................................................................................................................... 8

2.2 Project Background ......................................................................................................................... 9

2.3 Project Location ............................................................................................................................ 10

2.4 Project Scope ................................................................................................................................ 10

3. PROCESS DESCRIPTION ................................................................................................................. 12

4.1 Gas Cooler, 903-HA-01 A/B/C , ..................................................................................................... 15

4.2 Fuel Gas Scrubber, 903-VS-01 AB/C .............................................................................................. 16

4.3 Gas Filter Coalescer, 903-FR-01 A/B/C,......................................................................................... 17

4.4 Electric Heaters, 903-EH-01 A/B/C................................................................................................ 18

5. CONTROL PHILOSOPHY ................................................................................................................. 20

5.1 Gas Cooler, 903-HA-01 A/B/C ....................................................................................................... 20

5.2 Fuel Gas Scrubber, 903-VS-01 A/B/C ............................................................................................ 20

5.3 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C .................................................................................. 20

5.4 Fuel Gas Heater, 903-EH-01 A/B/C, .............................................................................................. 20

5.5 Pressure Regulators, ..................................................................................................................... 21

6. SAFEGUARDING PHILOSOPHY ....................................................................................................... 21

6.1 High High Pressure Protection of the System ............................................................................... 21

6.2 High High Temperature Protection of the System ........................................................................ 22

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6.3 Low Low Temperature Protection of the System ......................................................................... 22

6.4 Gas Cooler, 903-HA-01 A/B/C, ...................................................................................................... 22

6.5 Fuel Gas Scrubber, 903-VS-01 A/B/C, ........................................................................................... 23

6.6 Fuel Gas Filter Coalescer, 903-FR-01 A/B/C, ................................................................................. 23

6.7 Fuel Gas Heater, 903-EH-01 A/B/C, .............................................................................................. 23

6.8 Fire and Gas Detection Safeguarding............................................................................................ 24

7. Vent and Depressurization Philosophy ......................................................................................... 26

8. Start-up & Shutdown Philosophy.................................................................................................. 26

10. Isolation Philosophy ...................................................................................................................... 29

11. MAINTENANCE Philosophy ........................................................................................................... 29

12. Manning Philosophy ..................................................................................................................... 29

13. Draining philosophy ...................................................................................................................... 29

14. SAMPLING philosophy .................................................................................................................. 29

15. Sparing Philosophy ........................................................................................................................ 30

16. References .................................................................................................................................... 31

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