Contract

Page
1 of 12

File Reference

Number:P1007

1007-DISQ-0-S-MA-54008-Rev.3

RWE Dea

Disouq Field Development

FEED

Mechanical Handling Philosophy

Document number
1007-DISQ-0-S-MA-54008

30.01.12

Re- Issued for client approval

D Sami

A Fawzi

A Hamdan

RWE

23.01.12

Re- Issued for client approval

D Sami

A Fawzi

A Hamdan

RWE

10.01.12

Issued for client approval

D Sami

A Fawzi

A Hamdan

RWE

21.12.11

Issued for Client Comments

D Sami

A Fawzi

A Hamdan

RWE

Rev

Date

Description

Issued By Checked By Approved

By

Client
Approval

Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
CONTENTS
LIST OF ABBREVIATIONS ..................................................................................................... 3
1.0

INTRODUCTION ........................................................................................................... 4

1.1

Purpose of Document ................................................................................................ 4

1.2

Mechanical Handling Objectives ................................................................................ 5

2.0

ACCESS AT EQUIPMENT............................................................................................ 6

2.1

General Considerations ............................................................................................. 6

2.2

Equipment Located in Enclosed Rooms .................................................................... 6

2.3

Vessels / Tanks with Internals ................................................................................... 6

3.0

DEFINITION OF MECHANICAL HANDLING EQUIPMENT ......................................... 7

3.1

Marking ...................................................................................................................... 7

3.2

Permanent Mechanical Handling Facilities ................................................................ 7

3.3

Mobile Mechanical Handling Facilities ....................................................................... 7

3.4

Temporary Mechanical Handling Facilities ................................................................ 7

3.5

Lifting Accessories ..................................................................................................... 7

4.0

MECHANICAL HANDLING CRITERIA......................................................................... 8

4.1

Manual Handling Limits .............................................................................................. 8

4.2

Criteria for Use of Permanent / Mobile or Temporary Mechanical Handling

Equipment............................................................................................................................ 9
5.0

LIFTING FACILITIES AT EQUIPMENT ...................................................................... 10

5.1

Lifting Equipment Specification ................................................................................ 10

5.2

Use of Equipment Structural Beams ........................................................................ 10

5.3

Storage and Use of Lifting Equipment Accessories ................................................. 10

6.0

EQUIPMENT HANDLING AND ACCESS ROADS ..................................................... 11

6.1

Equipment Handling................................................................................................. 11

6.2

Access Ways ........................................................................................................... 11

7.0
7.1

DETAILED DESIGN DELIVERABLES ....................................................................... 11

Mechanical Handling Study ..................................................................................... 11

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
LIST OF ABBREVIATIONS
Abbreviation

Definition

ALARP

As Low As Reasonably Practical

Disouq

Disouq Development Project

EPC

Engineering Procurement & Construction

kg

Kilograms

MHO

Manual Handling Operations

SWL

Safe Working Load

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
1.0

INTRODUCTION
RWE Dea Egypt has discovered seven natural gas reserves in the Disouq
Concession within the onshore Nile Delta, starting in 2008, as shown on the
concession map below. Further exploration in the concession is ongoing. RWE Dea
Egypt is the operator of the Concession with EGAS as a partner.

The selected development comprises a central gas treatment site near NSG-1x,
where the gas is collected, treated by means of Low Temperature Separation utilizing
the Joule Thomson effect to achieve gas quality, and compressed for export. Treated
gas is transferred via a 16 pipeline directly into the GASCO NTS pipeline.
The well fluids are gathered and fed to a common inlet separator at the central plant.
All gases and liquids will be separated and processed on the central treatment site
into sales gas, stabilized condensate, and free production water.

Treatment of gas is carried out in two trains, while treatment of condensate is in a

single train. Three trains of sales gas compression are installed. Fuel gas for the gas
engine drives is taken from the suction of the sales gas compressors.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
1.1

Purpose of Document
This document describes the mechanical handling philosophy to be adopted for both
the Disouq central plant and well sites to ensure that installation, operation,
maintenance and mechanical handling requirements are considered and integrated
within the overall layout and equipment design.

1.2

Mechanical Handling Objectives

The single overriding objective is to ensure the safe handling of materials and
equipment both for central plant and well sites when carrying out installation,
operation and maintenance activities. This shall include provision of lifting facilities
and space to permit operations, dismantling and re-assembly of equipment during
operation maintenance and repair.
The extent of operation and maintenance undertaken on the well sites will be
minimised. Delicate or highly skilled maintenance tasks will not be attempted on well
sites. The approach will be to change-out rather than repair equipment if it fails in
service or is due for an overhaul.

The mechanical handling equipment specifications and installation, operation and

maintenance procedures to be developed during detailed engineering shall reflect the
following requirements:

Ensure compliance with all project safety considerations in regard to safe

materials handling.

Review and implement all relevant legal requirements and recognised

standards and codes of practise for safe lifting and handling.

Incorporate features into the design that will both provide for and minimise the
time needed for carrying-out installation, operation, maintenance and repairs.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
2.0

ACCESS AT EQUIPMENT

2.1

General Considerations
Plant layout and detailed design shall give consideration to the following:

Ensure adequate access for operation and ease of operation

2.2

Ensure adequate access and withdrawal space is provided to operate,

inspect, repair and carry out in-situ maintenance and/or component removal
(where required)
Ensure the detailed design facilitates equipment removal (i.e by providing
breakout flanges)
Ensure adequate provision for lifting and pulling points for equipment removal
in accordance with allowable weight limits
Ensure adequate access for use of specialist maintenance/removal
equipment (where required)
Ensure that equipment pre-defined withdrawal requirements and spaces
(where required) are fully evaluated and subsequently defined on general
arrangement drawings and addressed in equipment maintenance manuals
Provide permanent access including ladders and platforms, where necessary,
to all equipment, hydraulically actuated valves, relief valves and instruments
requiring calibration. Pipework and equipment shall be located so as not to
obstruct access for maintenance.
Equipment Located in Enclosed Rooms
Where equipment is located indoors it shall be designed so that component parts can
be dismantled by hand or with the aid of sack trolleys or manual four wheeled trucks
and removed through doorways. For electrical equipment such as control panels it is
unlikely that the whole panel would be removed. Typical items to be removed will
include control panel rack units, circuit breakers and UPS batteries. Consequently,
equipment rooms will not be provided with hatches for crane access or built in
mechanical handling equipment. If during the mechanical handling study (section 7.1
herein) a need is identified for mechanical handling equipment then the use of
temporary or mobile mechanical handling equipment shall be specified.

2.3

Vessels / Tanks with Internals

Vessel and tank manways shall be provided with a davit arm for removing manway
covers. Vessel internals shall be designed to pass through manways.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
3.0

DEFINITION OF MECHANICAL HANDLING EQUIPMENT

3.1

Marking
All lifting equipment shall be clearly marked with the Safe Working Load (S.W.L).

3.2

Permanent Mechanical Handling Facilities

Permanent mechanical handling facilities are considered to include:

3.3

Fixed runway beams /monorail

Fixed padeyes

Fixed pulling posts

Mobile Mechanical Handling Facilities

Mobile mechanical handling facilities are considered to include:

3.4

Demountable A-Frame type gantrys

Shear legs

Jacking systems

Beam clamps

Beam trolleys

Chain blocks

Chain lever blocks

Tirfors (wire rope hoists)

Cranes

Forklifts

Slings

Temporary Mechanical Handling Facilities

Temporary mechanical handling facilities are considered to include:

3.5

Rigged load bearing scaffolding

Lifting Accessories
Mechanical handling accessories are considered to include:

Wire rope

Chain

Shackles

Pulley blocks

Strops

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy

4.0

MECHANICAL HANDLING CRITERIA

4.1

Manual Handling Limits

The limit for manual handling per person is normally about 25kg and it is suggested
that this limit be adopted. Where manual handling is required, it is assumed that such
activities will be subject to satisfactory outcome of an operational risk assessment in
order to reduce identified risks to ALARP (As Low As Reasonably Practical).
a)

The maximum recommended load of 25kg per person (for males) relates to
a specific position or lifting in relationship to the human body.

b)

When handling loads it is recommended that the following de-rating system

shall apply

c)

Lifting Capability of a 2-person team = 2/3 x sum of their individual

capability (which equals 33.3kg max)

Lifting Capability of a 3-person team = 1/2 x sum of their individual

capability (which equals 37.5kg max)

However, if after the risk assessment for the load activity (in accordance
with Local Regulations or Operating Procedures) has been undertaken and
it has been established that the assumption in (a) above is incorrect (ie the
lift weight exceeds the maximum combined lift weights after de-rating), then
additional mechanical handling facilities must be provided.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
4.2

Criteria for Use of Permanent / Mobile or Temporary Mechanical Handling

Equipment
The criteria for installing permanent mechanical handling facilities at well sites and
CTP are based on weight and expected frequency. Facilities shall be provided as
follows:

Load < 25kg

No mechanical handling facilities required

manual handling

25kg < Load < 1000kg

Mobile or temporary mechanical handling

facilities to be provided
Depends on access in packages. May need
installed pulleys

Load > 1000kg And

Frequency > 1 per year

Load > 1000kg And

Frequency < 1 per year

Permanent mechanical handling facilities to

be provided

Mobile or temporary mechanical handling

facilities to be provided

A list of mechanical handling equipment shall be prepared for the Disouq

Development as part of the detailed engineering design to be carried out by the
selected Engineering Contractor.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
5.0

LIFTING FACILITIES AT EQUIPMENT

5.1

Lifting Equipment Specification

The specification of typical lifting equipment shall include, but not be limited to, the
following:

5.2

Generally, air-powered hoists shall be specified.

Permanently installed Electrically Powered mechanical handling equipment

and accessories shall be of flameproof construction (explosion proof
dependent on area classification), Non-powered handling equipment and
accessories shall be of non-sparking construction to permit use in hazardous
areas.

The materials used in the construction of the equipment should be suitable for
use on an onshore environment.

All lifting equipment should be inspected and tested by competent lifting

equipment specialists and supplied with test certification in accordance with
statutory codes / local regulations.

Use of Equipment Structural Beams

Equipment Structural beams may be used in conjunction with beam clamps or beam
trolleys. Where it is proposed to use such beams, they shall be checked for utilisation
capacity in regard to the additional loads imposed and structural calculations shall be
prepared by each supplier.
Structural beams designated for lifting shall be considered as lifting equipment and
shall be entered into relevant equipment maintenance schedules and be subjected to
the requirements of relevant legislation, testing and marking requirements.
All beams with moving pulleys and cranes must be fitted with end stops to avoid
excess travel of the crane.

5.3

Storage and Use of Lifting Equipment Accessories

Mobile mechanical handling equipment and lifting accessories for use on well head
shall be stored on weatherproof container(s) to be ready to be transferred to well
head site(s). Inspection and re-certification of equipment shall be undertaken
annually.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
6.0

EQUIPMENT HANDLING AND ACCESS ROADS

6.1

Equipment Handling

6.2

Equipment movement at any area shall generally be along designated access

routes to laydown areas from where items can be accessed by a suitable
crane.

Access Ways

Access ways and roads shall be provided where equipment may need to be
removed to designated laydown areas.

Piping runs and cable trays shall not block access ways or restrict access to
lifting facilities.

7.0

DETAILED DESIGN DELIVERABLES

7.1

Mechanical Handling Study

A mechanical handling study shall be undertaken during detailed design of the
facilities to examine the detailed requirements for mechanical handling, including but
not limited to:

Review of well head site(s) and Central Treatment Plant CTP equipment to
establish installation, operation and maintenance activities required and the
associated details of equipment items handled, operation maintenance lifting
loads, mechanical handling methodology and transportation to its designated
maintenance work shop.

Well workover activities including wireline and slickline requirements

Incorporation of sand removal facilities

A detailed Mechanical Handling Method Statement shall be provided by Construction

Contractor indicating risk assessment and procedures during installation and
Construction.
As identified in section 4.1 the full mechanical handling study shall cover loads
greater than 25kg. Loads less than this are provisionally identified as loads to be
manually handled (dependent upon operational risk assessments, taking into
consideration chemical hazards).
As part of the above mechanical handling study a drawing shall be prepared by
detailed engineering contractor to indicate full details of access routes, laydown areas
and location of runway beams, padeyes and pulling posts together with their
respective load capacities (S.W.L).
The study shall also consider the following:
1. Vessel internals are to be removable through vessels manways.
2. Vessels manways, in which the centreline is >=1.5 metres above ground will
require permanent access platforms.
3. Permanently installed fixed lifting devices shall be provided for equipment with
maintenance loads exceeding 500 kg.

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Onspec Engineering Solutions

Disouq Field Development Project
Mechanical Handling Philosophy
In addition, the operation and maintenance manual shall identify/specify for larger
equipment packages requirements for internals removal, removal methods and
devices.

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