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Contract No : CE-1802
Company:
Contractor:
Page 1 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
TABLE OF CONTENTS
1. Introduction 3
2. Problem Description 3
3. Technical Proposals 3
4. Scope of work: 4
5. Material Take-Off 7
6. Conclusion 8
7. Attachments 9
Page 2 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
1. Introduction:
After the sabotage of the Al-Shaer Gas field, Ebla Petroleum Company contracted
with ASAS Contracting Ltd. to rehabilitate Al-Shaer Gas Gathering Station.
2. Problem Description:
The Bypass line is a sectional piping and limited from both ends by shutdown
valves 200-XV-2001 & 701- XV-3150 and manual valves U/S & D/S mentioned
XV’s and rated at 600#.
As long as Flowlines & Production Header rating is 1500#, the main scenario to
over pressurize Bypass line is:
Passing of 200-XV-2001, and malfunction of 701- XV-3150, or inadvertent action
to close manual valves U/S & D/S 701- XV-3150.
3. Technical proposal:
There are Three Proposed Solutions to solve the above mentioned Problem.
Page 3 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
Installation of PSV on the bypass line will be a mechanical protection against over
pressurization, its set point will be matching with piping rate of the bypass line.
Sizing of this PSV will depend on the worse scenario expected during process
operation, so blocked outlet scenario for total production shall be considered for
PSV Sizing, hence its size will be similar to 302-PSV-100A/B installed on
production separator 302-V-001.
Inlet and outlet piping arrangement of this proposed PSV will be 4” L 6”, then the
outlet line connecting to main flare header will be 20”.
As there are a different piping classes between the inlet manifold and the bypass
line, so that installation of 8” XV at inlet of bypass line (Down-stream of
200-XV-2001) will increase layer of bypass line protection.
Function of this new XV will be related to function of 200-XV-2001, where all
signals that cause to close it, they will close the new XV at the same time.
Once two XV’s are closed, double isolation will be met, then gas source that cause
over pressurization will be shut off.
As mentioned above the two options require a new installation that needs allocated
budget and time, so removal of bypass line will prevent the potential risk of bypass
line over pressurization and the new installations.
4. Scope of work:
The PSV Size will be 4” L 6”, 600# x 150#, Set @ 95.2barg (the same size and
setting of the PSV of the Production Sep. 302-PSV -100A/B).
Page 4 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
The inlet line of the PSV will be fabricated and installed from an 8” , CS
piping Sch-80 ASTM A-106 , Isolation Full bore Ball valve 8”x 600# CS
Body, will be installed upstream of the PSV.
The length of the inlet piping will be approximately 15 m and the PSV will be
installed on the top Platform of the Inlet manifold.
The PSV outlet Line will be fabricated and installed from a 20” Piping , SS
316L , Sch- 5S and will be laid down and routed parallel to the 4” Inlet
Manifold Flare Header and will be connected to the Main Flare Header of
Shaer GGS at the 20” Section.
The Length of the PSV outlet line will be approx. 250m of SS Piping.
Downstream the PSV a 20” isolation Full Bore Isolation Valve, SS Body and
Trim.
Steel Structure and Piping Supports will be fabricated and installed.
Page 5 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
Cold cut the 16” Header where the bypass piping start in addition to
the 900# class fittings and flanges. Remove 3m 16” section from the
Header.
After gas test, hot work can be taken place (grinding, beveling and
welding).
Weld and install new 3m pup piece 16” instead of the removed piece,
CS, sch-160 ASTM A-106 Gr. B.
The welding of the new Section will be Golden weld (Golden weld
Procedure to be applied).
At the bypass Tie in point to the Truck line, Cut the Tee and install
& weld 16” Pup Piece instead of it, the specifications of this piece
will be the same specifications of the trunk line. (This weld will be
golden weld).
Note: In order for this study to be implemented the lines (16”-200-PG-1002-17D-V &
16”-200-PG-1004-17D-V) shall be 1500# Fully Rated.
Page 6 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
5. Material Take-Off
Page 7 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
6. Conclusion:
Page 8 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Document Title: Document No.:
TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER PRESSURIZATION CE-1802-PR-300-RPT-0004-00
7. Attachments:
Page 9 of 9