OPERATIONS AWARENESS

101

© 2018 PETROLIAM NASIONAL BERHAD (PETRONAS)

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 Objective

• To brief on well pad and FCP facilities.

• To highlight the wellhead and FCP potential

hazards.

• To share the safety practice.

 Field Overview/Layout: Current FCP Facilities

GIFT

Water intake Crude tie-in point FCP Facilities Wellpad Garraf Base
facilities camp (GBC)

Trunkline from Roads Crude Export Water Intake Gas Processing

Wellpad Pipeline pipeline Plant (GPP)

Garraf Integrated Garraf Integrated

Power Plant GIFT
Control Centre Facilities & Terminal
(GICC)
 Overall Production Facilities Layout
Water
Intake at
Garraf
Wellpad Sizing
Garraf Base River Year Name Size
Camp Mishrif
Ga-3 1
WP-G Ahdeb A 9
Tie-in 2013 B 9
P (Ga-1) 3
il Q (Ga-4) 8
v yO E 28
Ga-3 WP-B ea 2014

iver
H F 28
12” 15km Light Oil km
”8

Highw
fR
18 J 28
True North 2015

Garra
PL WP-E C 28
28” 107km Heavy Oil

ay # 7
r e
v e ak
D 28
2018
Ri Int
ird ter H 21
Th Wa

Badra – Garraf G 14
2019
om m

Tie-in WP-C K 35
Fr 32k

WP-D Yamama / Zubair / Ratawi

”
28

WP-P B 7
Ga 2027 D 7
rr af GIFT WP-A H 7
Co
il
tO

ntr WP-Q
act
Ligh

WP-H
PG

Ar WP-F
ea
km L

Bo
2 km

Legend un
da
9

8” 9 2

Road ry
28”

River WP-K
Light Oil Pipeline WP-J
Dry Gas Pipeline
LPG Pipeline
Gas

Heavy Oil Pipeline Yamama Wellpad

Dry

Water Intake Pipeline

Mishrif Wellpad
6km

Mishrif FWS Pipeline

Yamama FWS Pipeline
2 0” 7

Water Injection Pipeline Future Wellpads

4
 Off-Site Process Diagram

WPF
8 wells

Sector 1 : WP-A , P , Q WPC

5 wells
Sector 2 : WP-E , B , GA-3
Sector 3 : WP-C WPA WPB
WPJ 9 wells 9 wells
Sector 4 : WP-J , F 4 wells
Ga-3
OGF single well

Oil
Gathering
Facilities
WPP
3 wells

WPE
FCP- GATHERING STATION 10 wells

WPQ
6 wells
TRAIN 1 TRAIN 2

5
 FCP Process Diagram
GTU

Fuel Gas

FGCU Power Plant LP Flare

From wellpads Gathering

Station 2nd Stage Dehydrator
Train 1 1st Stage Separator Crude
Separator Press: 7 bar
(50,000bbls) Press: 10 bar Heater
Press: 2.5 bar Water 0.2%
( 18” Trunkline)
Charge
Pump

Rundown
Off-spec
Cooler
T-1700

Crude oil Desalter

Storage Tank Press: 6.7 bar
Booster &
Salt 10 PTB
Custody
Export
Meter
pump
On-spec
AHDAB PIPELINE

T-1400 A
7,950 KL Two Fixed Roof Crude day
( 18” 8 Km) Crude oil storage tanks (2x50,000
Storage Tank
bbl working vol)

On-spec
T-1400 B
7,950 KL
Overall Crude Process Description
Facilities Photos

EXPORT PUMP

POWER PLANT

FLARE STACKS

STORAGE TANKS

8
 CCR Operations
CENTER CONTROL ROOM
 DCS (Distributed Control System )
- Function Distributed Control System is specially designed with redundancy and diagnostic capabilities to improve control
reliability and performance. It gives greater flexibility to control distributed discrete field devices and its operating stations.

 SIS ( Safety Instrumented Systems)

- Function The Safety Instrumented Systems are used to monitor the condition of values and parameters of a plant within the
operational limits and, when risk conditions occur, they must trigger alarms and place the plant in a safe condition or even at the
shutdown condition ( SOL).

 F&G ( Fire and Gas Systems)

- Function Fire & Gas systems are designed to monitor environmental conditions and detect those variations that can be
associated with an incipient fire or gas leakage.

 PAGA System (Public Announcement General Alarm)

- Function Public Address General Alarm communications from CCR to Field .

 CCTV ( Close Circuit Television)

- Function A CCTV System or Closed Circuit Television System is a security system formed from 1 or more CCTV cameras
which send or broadcast their own signals to one or more locations. These video pictures  from the camera can be viewed in real
time or recorded. 

 Weather broadcast.
- Function Information wind speed and outside Temperature to monitor plan activity outside.

 ERT ( Emergency Respond Team).

- Function Emergency Respond Team control center in FCP, Incase Fire and etc.
Wellhead

A wellhead is the component at the surface of an oil and

gas well that provides the structural and pressure-
containing interface for the drilling and production
equipment

The primary purpose of a wellhead is to provide the

suspension point and pressure seals for the casing
string that run from the bottom of the hole sections to the
surface pressure control equipment
Well Flowline

Well flow line is a connection line from the wellhead

to Production Manifold. It is designed to transfer
process media (oil, gas and water) under high
pressure. The flow line is equipped with number of
sensors which give information about the flow such as
pressure, temperature and in some cases flow rate.
Chemical Skid

Chemical skid is connected to the well flow line with

the purpose to inject desired chemicals to the flow.
Chemical skid consist of storage tank, pump and high
pressure tubing.
Chemicals can be different type and depends on
Crude composition.
At all wellpads in Garraf field installed Corrosion
Inhibitor and Antifoam Inhibitor injection skids
Production Manifold

Production manifold is high pressure pipeline normally

bigger diameter than flow line equipped with valves,
fittings, sensors and safety equipment. The main
purpose of the manifold is to connect all flowlines from
the wellheads and divert the flow to export
line/trunkline to FCP for further process.
Production manifold is also equipped with test separator
and allows to test any well separately.
Closed Drain System

Close drain system consist of the vessel, pipeline and

tubing, transfer pump. The purpose of the system is
collect all drained liquid and store it in the vessel.
Normally the vessel is located lower than ground
level allowing all liquids drained from pipelines to be
collected in the vessel.
Drainage is required to empty the pipeline during
maintenance activity and process upset.
All draining lines from the wellpad are underground
and lined to the CD vessel.
MPU & Process Substation

Power for all equipment at wellpad is supplied from

Mobile Power Unit (portable diesel generator). Two
MPUs available at each location (1 online, 1 standby).
There are diesel storage tank located near MPU. The
tank capacity is designed to maintain continues fuel
supply to MPUs for about 1 week.
MPU supply power to Main Substation (MSS). The
power from MSS is supplied to equipment through
distribution system.
FCP Facility - Power Plant

Power Plant is located inside the FCP area.

Power Plant is producing energy to supply all
equipment including pump motors, instrument
equipment, lighting etc.
Power generated by diesel and gas driven engines is
transferred by high voltage cables and through
Overhead Transmission Line to transformers and
distributed to all users from Electrical Sub Stations.
At FCP area the equipment is supplied through high
voltage cables which lays in cable trays or underground.
OHTL Overhead Transmission Line is aimed to transfer
the power from FCP Power Plant to remote locations
like Wellpads.
 FCP FACILITY: PROCESS EQUIPMENT AND FLARE SYSTEM

Gas Crude oil received from Wellpads contain gas, water,

salt and some sediments which need to be separated
Prod. from the oil in order to get final product – Export Oil.
Separation &
from Oil
The purpose of the Process Equipment is to
Treatment clean/separate the oil from all associated and
Wells unwanted products.
Gas separated from the oil during separation is
Water diverted to the gas utility system and excess to the
Contaminants Flare System
Produced water to Evaporation Pond
Contaminants remains in separator
The Oil is transferred to Storage Tanks
FCP FACILITY: STORAGE TANKS

There are two Storage Tanks and one Off-Spec tanks

built at FCP.
Storage tanks filled with oil after treatment and meets
all specific requirements (salt content , gas content and
water content).
Off-Spec Tank is used to collect the oil which content
more contaminants and has to be transferred back to
Process.
FCP FACILITY: EXPORT PUMPS & METERING STATION

Treated/processed oil from Storage Tanks are

transferred by high capacity Export Pumps through
Metering Station to Export pipeline.
There are three Export Pumps installed at FCP in
normal operation two pumps working another one
standby.
The purpose of Metering Station is calculate how much
oil was pumped out from FCP.
Export line from FCP is connected to Ahdeb main oil
transfer line which transfer the oil to Basra Tank Farm.
 HEALTH SAFETY AND ENVIRONMENTAL HAZARDS

Hydrocarbon in liquid and gas

High working pressure in pipeline

Toxic chemicals

Electricity

Confined spaces

H2S

Rotating equipment

Underground piping and cables

 SAFETY PRECATIONS

In order to avoid any incidents and process upset all visitor are obliged to follow PCIHBV Safety
Rules and Regulation which stipulated in ZeTo Rules:

1. Work with a valid work permit (PTW) required by the job;

2. Verify energy isolation before starting work;
3. Obtain authorization before overriding or disabling safety critical equipment;
4. Obtain authorization before interring a confined space;
5. Protect yourself against a fall when working at height;
6. Use the correct PPE when handling hazardous chemicals;
7. Obtain authorization before excavation or entering a trench;
8. Do not position yourself under suspended load;
9. Do not smoke outside designated areas or bring potential ignition source into process areas
without authorization;
10. Do not use your mobile phone/walkie-talkie while driving; follow the speed limit and use seat
belt
 PERMIT TO WORK SYSTEM

Please be aware that for all activities carried inside the wellpad area all contractors and
visitors must obtain Permit To Work certificate. Only approved and valid permit will allow to
do any activities inside the wellpad area. Examples of activities:
1. Vehicle entry;
2. Taking photo;
3. Excavation works;
4. Lifting loads;
5. Instrumentation calibration;
6. Entering wellhead cellar;
7. Portable generators using;
8. Etc.

Request for PTW to be applied to Production Operation representative at site ONLY

 Garraf Facilities Growth by 2020
Facilities Current (October 2018) FDP Phase 1 (Q4 2020) *
Process Trains 2 4 + 1 (Leased Oil Train)
Wellpads 9 13
Wells 62 196
(Oil) 146 (Oil) + 50 (WI)

Infield Pipelines 9 23
(Oil) 12 (Oil) + 11 (WI)

Export / Trunk Pipelines 1 4

(HOTS 1) 2 (HOTS 1 & 2) + 1 (WI)
+ 1 (Export Gas)

Power Plant 1 2
(15 MW) (15 +72 MW)

Water Management Plant 1 17

PWT (1 train) PWT (1+3 trains)
RWT (3 trains)
WIT (10 trains)

Gas Processing Plant 2 3

(GTU & FGCU) (GTU, FGCU, GDP)
 Thank you
Terima kasih
‫شكرا‬
ありがとうございまし
た

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