Lessons Learned

Implementation
Workshop Summary
BI#: 10-01413
Project Title: Install Flare Gas Recovery System at
Khursaniyah Gas Plant
Project Phase: DBSP Phase
Prepared by: Abdulmajeed Almoumen
VMPSC Facilitator
3/12/2024

Saudi Aramco: Company General Use

 Lessons Learned Implementation Report

BI-10-01413 Install Flare Gas Recovery System

at Khursaniyah Gas Plant

DBSP (Pre-FEED) Phase

Project Classification: C
Event Date: Tuesday | March 12, 2024
Venue: KBR Office, Al Khobar

Report Version Control:

Version Date Author Change Description
st
DRAFT 1 03/23/2024 Abdulmajeed Almoumen Issued for review and comment
nd
DRAFT 2 Abdulmajeed Almoumen Issued to PMOD for review and
comment
FINAL Abdulmajeed Almoumen Final issue
 3

Saudi Aramco: Company General Use

 Table of Contents
1.0 Introduction.....................................................................................................4
1.1 Background.....................................................................................................4
1.2 Purpose of the Project...................................................................................4
1.3 Project Location..............................................................................................5
2.0 LLI Workshop Summary................................................................................8
3.0 LL Implementation Guidelines......................................................................9
4.0 Appendix A: Lessons Learned Selected for DD Phase.............................10
5.0 Appendix B: Workshop Participants..........................................................22

Saudi Aramco: Company General Use

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Saudi Aramco: Company General Use

 1. Introduction

1.1. Project Objectives

The primary objective of this project is to install a flare gas recovery system at
Khursaniyah Gas Plant (KGP) to comply with Saudi Aramco standards towards
protecting the environment.

Presently, Khursaniyah Gas Plant (KGP) has an average routine flaring rate of 2
MMSCFD, resulting in Greenhouse Gas (GHG) being emitted into the
atmosphere.

KGP Flare Gas Recovery System (FGRS) project has been identified as part of a
company-wide flare minimization plan to achieve zero flaring by 2030. This
project is part of the Corporate Environmental Master Plan.

1.2. Scope Brief

Install FGRS to recover the flare gas from the High Pressure (HP) flare, Low
Pressure (LP) flare, Acid Gas (AG) flare and Cold Flare (CF) Systems.

A common flare gas recovery header (24”) will be added by connecting all the
flare lines and routing to the existing Atmospheric Compressor.

1.3. Project Location

Saudi Aramco: Company General Use

 PLOT PLAN LAYOUT

For more details refer to GES+ SOW and Project Scoping Paper.

Saudi Aramco: Company General Use

 2. LLI Workshop Summary

The LLI workshop was conducted on the 12th of March 2024 for BI-10-01413 Install Flare
Gas Recovery system at Khursaniyah Gas Plant at DBSP Phase. The session reviewed
lessons applicable based on cost and schedule impact. The workshop involved examining
the project scope using different areas of focus, emphasizing items with significant
impact and urgency, to develop preventive actions and avoidance strategies. The team
captured applicable lessons in the implementation worksheet (Appendix A).

Areas discussed and number of lessons selected are summarized below:

Number of Lessons
Areas of Focus based on Impact Severity Selected
Management 01

Contracting 02

Planning and Scheduling 02

Interface Planning 01

Hot Tap, Stopple & Tie-In Planning 02

Scope Definition & Control 06

Field Verification 02

Mechanical 01

Piping 01

Electrical 02

Additional Lessons 13

Total Lessons Discussed 33

A total of 33 lessons and design deficiencies extracted from similar projects were
shared and discussed during the workshop (Appendix A) and assigned action plans and
target dates.

Saudi Aramco: Company General Use

 3. LL Implementation Guidelines

This report shall serve as a starting point for implementing preventive actions and
avoidance strategies/recommendations highlighted. Conducting periodic Lesson Learned
round-table meetings will also contribute greatly to the success of your efforts.

 IPT Leads shall develop preventive actions for each LL topic listed in
Attachment 1.
 Responsible person from concerned organization shall be assigned as owner
of the selected lesson(s)
 LL owner shall assure actions are measurable, precise and feasible within the
project phase
 All selected LL shall be implemented/executed within the proposed dates.

Saudi Aramco: Company General Use

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Saudi Aramco: Company General Use

4. Appendix A: Selected Lessons Learned

Phase Impact Urgency Action Items

S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
1.0 Management

Ineffective
KBR (Tanveer
planning and KBR shall prepare the level
Khan)/ SAPMT
1 1.6 management of Pitfall 1.6     M H II EPC schedule for SA 14/04/2024 Ongoing
(Abdullah Al-
interfaces among review and approval
Ghamdi)
all parties

2.0 Contracting

Inadequate KBR shall supervise the KBR (Tanveer

supervision of work of the sub-contractor Khan)/ SAPMT
2 2.3 Pitfall 2.3    H M 15/05/2024 Ongoing
subcontractor by to ensure the quality and (Abdullah Al-
main contractor schedule compliance Ghamdi)
Obtain Waivers to
Expedite
3 2.21 Processing of hdgp56    No waivers are anticipated Closed
OOK Invoices &
Change Orders
4.0 Planning & Scheduling

Insufficient level KBR shall prepare the level KBR (Tanveer

4 4.1 Pitfall 4.1  M H 14/04/2024 Ongoing
of project II EPC schedule for SA Khan)/ SAPMT
11
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
schedule
development
(Abdullah Al-
during DBSP and review and approval
Ghamdi)
Project Proposal
phase
Isolate New
Construction Sites This will be evaluated
5 4.7 crwr-100   Ongoing
from Operating during the CS workshop
Facilities
5.0 Interface Planning

KBR shall check, verify and KBR (Nazar/

Unexpected use
reserve the location of the Irfan)/ SAPMT
6 5.4 of reserved space Pitfall 5.4  L L 01/06/2024 Ongoing
equipment (valves and (Abdullah Al-
by other projects
Piperack) Ghamdi)

7.0 Hot Tap, Stopple, & Tie-in Planning

KBR shall capitalize on the
Incomplete
unit shutdowns if mot
evaluation of KBR (Nazar/
possible then hot-taps will
possibility to avoid Irfan)/ SAPMT
7 7.1 Pitfall 7.1  M M be considered and shall 01/06/2024 Ongoing
hot tap by (Abdullah Al-
identify the right Hot-taps
performing tie-in Ghamdi)
calculation during the PP
during shutdown
phase.
Limited resources KBR shall capitalize on the KBR (Nazar/
of Hot Tap Unit to unit shutdowns if mot Irfan)/ SAPMT
8 7.3 Pitfall 7.3  M M 01/06/2024 Ongoing
perform capital possible then hot-taps will (Abdullah Al-
project work due be considered and shall Ghamdi)
12
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
to higher priority identify the right Hot-taps
given to calculation during the PP
maintenance work phase.
8.0 Scope Definition & Control
Inadequate
participation by all
stakeholders and
other necessary
9 8.1 Pitfall 8.1      See PPTA workshop Closed
authorities during
design
development and
review
Incomplete
investigation of KBR shall conduct the
KBR (Tanveer
actual conditions topographical survey and
Khan)/ SAPMT
10 8.2 at project site, Pitfall 8.2    M M GPR at project location to 01/06/2024 Ongoing
(Abdullah Al-
including investigate the actual
Ghamdi)
feedstock conditions at project site
composition

KBR (Tanveer
Underutilizing
khurais- KBR shall prepare the 3D Khan)/ SAPMT
11 8.6 benefits of 3D     L L 01/02/2025 Ongoing
051 model during the PP phase (Abdullah Al-
model
Ghamdi)

KBR shall conduct the 30%

KBR (Tanveer
Effective Planning and 90% design review and
Khan)/ SAPMT
12 8.10 for Design crwr-110   L M shall reflect all the design 01/06/2024 Ongoing
(Abdullah Al-
Reviews comments regarding the
Ghamdi)
design

13
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y

Generate Overlay KBR shall generate overlay KBR (Tanveer

Drawings for khurais- and overlapping Drawings Khan)/ SAPMT
13 8.17  M L 01/06/2024 Ongoing
Facilities in the 051 for Facilities in the Same (Abdullah Al-
Same Location Location to avoid conflicts Ghamdi)

Ensure Clarity in
Refer to the project specific
Definition of Tie-in
14 8.25 hnrp-172    below points(17.03 to
& Modification
17.09)
Work Scopes

9.0 Field Verification of Existing Site Conditions

Overdependence KBR shall conduct the
KBR (Tanveer
on existing topographical survey and
Khan)/ SAPMT
15 9.2 documentation Pitfall 9.2    M M GPR at project location to 01/06/2024 Ongoing
(Abdullah Al-
instead of actual investigate the actual
Ghamdi)
verification in field conditions at project site
Insufficient
involvement by
experienced KBR shall supervise the KBR (Tanveer
designers and work of the sub-contractor Khan)/ SAPMT
16 9.3 Pitfall 9.3   H M 15/05/2024 Ongoing
knowledgeable to ensure the quality and (Abdullah Al-
operations and schedule compliance Ghamdi)
maintenance
personnel
11.0 Mechanical
17 11.1 Incomplete Pitfall 11.2   M M KBR shall ensure to KBR 01/06/2024 Ongoing
consideration of consider the maintenance (Adnan/Nazar)/
requirements for access and removal of SAPMT

14
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
maintenance
access and (Abdullah Al-
equipment
removal of Ghamdi)
equipment
12.0 Piping

KBR (Tanveer
3D Model
hwgpd- KBR shall prepare the 3D Khan)/ SAPMT
18 12.5 Development and   L L 01/02/2025 Ongoing
011 model during the PP phase (Abdullah Al-
Interface Issues
Ghamdi)

13.0 Electrical
Insufficient
coordination with
Power Systems KBR shall ensure proper
(PS) during coordination with Power KBR (Tanveer
design and Systems (PS) during DBSP Khan)/ SAPMT
19 13.1 Pitfall 13.1     L L 01/06/2024 Ongoing
procurement phase to review and (Abdullah Al-
phases to review approve electrical design Ghamdi)
and approve issues
electrical design
issues
KBR shall verify the existing
KBR (Tanveer
Design battery rooms size based
Khan)/ SAPMT
20 13.15 Considerations for insp-029     L L on the final size of UPS, 01/06/2024 Ongoing
(Abdullah Al-
Battery Rooms and in case if UPS is
Ghamdi)
upgraded to higher size.

15
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
17.0 Additional Lessons
Check for proper
equipment KBR shall check, verify and KBR (Nazar/
location to reserve the location of the Irfan)/ SAPMT
21 17.01 -  L L 01/06/2024 Ongoing
minimize later equipment (valves and (Abdullah Al-
revisions during Piperack) Ghamdi)
design

Securing EPD
KBR shall expedite the KBR (Tanveer
and NCEC
issue of the EIA study and Khan)/ SAPMT
22 17.02 approval for EIA -  H H 01/06/2024 Ongoing
obtain approval from EPD (Abdullah Al-
during DBSP
and NCEC. Ghamdi)
(Pre-FEED).

KBR (Shaik/
Interfaces (DCS, KBR shall finalize the
AbdullahAl-
ESD, UPS, MCC) interfaces requirements
23 17.03 -  M M Ashikh)/ SAPMT 01/06/2024 Ongoing
with the existing with the existing plant
(Abdullah Al-
plant control system.
Ghamdi)
KBR shall prepare the KBR (Tanveer
Initiate interface interface management plan Khan)/ SAPMT
24 17.04 -  L L 01/06/2024 Ongoing
management plan identifying all the interfaces (Abdullah Al-
with the existing facilities. Ghamdi)

Tie-in & Potential The proposed FGR tie-in KBR

Challenges for the location upstream the ATM (Nazar/Irfan)/
following items: Compressor is congested, SAPMT
25 17.05 -  M M 01/06/2024 Ongoing
• ATM and connection is (Abdullah Al-
Compressor tie-in required KBR shall conduct Ghamdi), FP
area early evaluation in the (Abdullah
16
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
design as it may require
piping modifications.
2-Consider adding a
moisture trap element to Alogaily)
capture any moisture in
order to protect ATM
compressor.
KBR
Verify the Piperack space (Nazar/Irfan)/
Tie-in & Potential
availability is required to SAPMT
Challenges for the
26 17.06 -  M M accommodate flare gas (Abdullah Al- 01/06/2024 Ongoing
following items:
recovery line to ATM Ghamdi), FP
• Pipeline rout
compressor (Abdullah
Alogaily)
KBR
(Nazar/Irfan)/
Tie-in & Potential SAPMT
Challenges for the The project shall consider (Abdullah Al-
following items: tie-in to main N2 and IA Ghamdi), FP
27 17.07 -  M M (Abdullah 01/06/2024 Ongoing
• Nitrogen header and avoid tapping
demand and into utility station line. Alogaily)
suitable tie in.

28 17.08 Tie-in & Potential -  M M The project should provide KBR 01/06/2024 Ongoing
Challenges for the a utility station in the new (Nazar/Irfan)/
following items: facility. SAPMT
• Utility Station – (Abdullah Al-
Flare Area Ghamdi), FP
(Abdullah

17
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y
Alogaily)
KBR
Tie-in & Potential (Nazar/Irfan)/
Challenges for the The project should provide SAPMT
29 17.09 following items: -  M M a bypass for FGRS main (Abdullah Al- 01/06/2024 Ongoing
• Instrument Air isolation valve. Ghamdi), FP
capacity. (Abdullah
Alogaily)
KBR shall check and verify
Draining of the if the is any condensation in
KBR
flare headers the system, then KBR shall
(Nazar/Irfan)/
between K.O provide a mechanism for
SAPMT
drums in flare draining potential
30 17.10 -  M M (Abdullah Al- 01/06/2024 Ongoing
area and condensed liquid in the flare
Ghamdi), FP
Receiving headers between K.O
(Abdullah
Atmospheric drums in flare area and
Alogaily)
compressors. Receiving Atmospheric
compressors.
Quantify the additional
demand of N2 and
KBR
Instrument air and analyze
(Nazar/Irfan)/
the current existing air
N2 and SAPMT
compressors/N2 production
31 17.11 Instrument air  M M (Abdullah Al- 01/06/2024 Ongoing
membranes where there is
demand Ghamdi), FP
a potential need to expand
(Abdullah
the existing
Alogaily)
system production for N2
and IA.

18
 Phase Impact Urgency Action Items
S D P D P C P H M L H M L
B P D R O E O I E O
Pitfall / T S O N C I D G D
Pitfall / Lesson Lesson P C S G W W Target
What Responsible
Link U / H Completio Status
(List of action Plans) Person
S H n Date
D
U
Y

KBR (Nazar)/
Exact materials KBR shall prepare the
SAPMT
32 17.12 specification for -  M M materials specification for 01/06/2024 Ongoing
(Abdullah Al-
the tie-in’s points the tie-in’s points.
Ghamdi)

KBR shall capitalize on the

unit shutdowns if mot
KBR (Nazar/
Identifying the possible then hot-taps will
Irfan)/ SAPMT
33 17.13 right Hot-taps -  M M be considered and shall 01/06/2024 Ongoing
(Abdullah Al-
calculation identify the right Hot-taps
Ghamdi)
calculation during the PP
phase.

19
5. Appendix B: Workshop Participants