Ce 1802 PR 300 RPT 0004 00

PROJECT : AL-SHAER GGS REHABILITATION PROJECT
(INTERMEDIATE STAGE)
Contract No : CE-1802
Company:
Ebla Petroleum Company - EBCO
Contractor:
ASAS Contracting Ltd.
00 05-08-2018 ISSUED FOR REVIEW AK HK/OHU Z.R

Rev. Date Description Prepared by Checked by Approved EBCO
by Approval
Document Title: TECHNICAL STUDY FOR GGS BYPASS LINE PROTECTION AGAINST OVER
PRESSURIZATION
Document Type: PROCESS DOCUMENT Rev.
Document No.: CE-1802-PR-300-RPT-0004-00 00
Page 1 of 9
Company: PROJECT : AL-SHAER GGS Contractor:
REHABILITATION PROJECT
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
3.1. First Proposal 4
3.2. Second Proposal 4
3.3. Third Proposal 4
4. Scope of work: 4
4.1. PSV Installation on Bypass Line 4
4.2. Additional XV installation D/S the Existing 200- XV-2001 5
4.3. Removal of bypass line 5
5. Material Take-Off 7
6. Conclusion 8
7. Attachments 9
Page 2 of 9
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.
ASAS started an integrated technical study of the project, followed by a HAZOP

Sessions.
HAZOP meetings was held from 24th to 26th, June 2018 at Dama Rose and from
25th to 26th, June 2018 at ASAS Company building, Damascus, Syria.
There were 65 recommendations as outcomes of these HAZOP session,
recommendation no 9 indicates to provide protection study in order to propose
safeguarding system that protects bypass line 600# rated from over pressurization
that lead to affect the bypass line when the pressure exceeds design pressure of
600# rated line.
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
3.1. First Proposal:
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”.
3.2. Second Proposal:
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.
3.3. Third Proposal:
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:
4.1. PSV Installation on Bypass Line:
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).
PSV Installation Scope Of work will include but not limited:
Page 4 of 9
 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.
4.2. Additional XV installation D/S the Existing 200- XV-2001:
Additional isolation Valve Scope of work will include but limited:

 Cut the 8” Bypass Line Downstream the Existing 200-XV-2001 , weld
8” 1500# Flanged and Install the additional XV , 8” 1500# .
 Install bleeding valve in between the two XV’s.
 Install addition tapping ¾” 1500# in order to install 3 PT’s for voting
1oo3.
4.3. Removal of bypass line:
The mechanical activities to remove the existing 8” Inlet Manifold Bypass

will include but it will not be limited to:
 Isolation, de-pressuring and purging wit N2 the subjected piping
section (EBCO action).
 Remove the 200-XV-2001 and the isolation Ball Valve 900#.
Page 5 of 9
 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
5. Material Take-Off
Shaer GGS - Bypass Safeguarding options - HAZOP Action
Option 1 ( PSV Installation )

Ser. Line Type Description Size Unit Qty
1 PSV PSV set at 95.2barg 4"x6" Pc 1
2 Pipe Pipe , CS , 8" SCH-80 8" m 15
3 Reducer Reducer Con. CS , Sch-80 8"x4" Pc 1
4 Flange Flange WN , RF 600# CS , Sch-80 8" Pc 2
5 Flange Flange WN , RF 600# CS , Sch 80 4" Pc 1
6 Elbow Elbow 90 , LR , CS , Sch-80 8" Pc 3
7 Inlet line Gasket Gasket SW. Graph. Fill , CR , 600# 8" Pc 2
8 Gasket Gasket SW. Graph. Fill , CR , 600# 4" Pc 1
9 Bolts Stud Bolts with Nuts for 4" x 600# 4" Pc 8
11 Tee Tee Equal , CS , SCH-80 , 8"x8" Pc 1
12 Ball Valve Ball valve , Flanged Full Bore , CS 8" , 600# 8" Pc 1
13 Flange Flange WN , RF 150# SS , Sch-5S 6" Pc 1
14 Reducer Reducer Con. SS , Sch-5S 6" x 12" Pc 1
15 Reducer Reducer Con. SS , Sch-5S 12" x20" Pc 1
16 Flange Flange WN , RF 150# SS , Sch-5S 20" Pc 2
Outlet line
21 Ball Valve Ball valve , Flanged Full Bore , SS 20" , 600# 20" Pc 1
22 Pipe Pipe , SS , 20" SS , Sch-5S 20" m 250
23 Elbow Elbow , 90 , LR , SS , Sch5S 20" Pc 8
24 Tee Tee Equal , SS , Sch- 5S , 20"x20" Pc 1
Page 7 of 9
Option 2 ( MTO for Additional XV , 8" 1500# )

1 ESDV ESDV, Ball Valve , Pneumatic Actuator 1500# 8" Pc 1
2 Flange Flange WN , RF 1500# CS , Sch-80 8" Pc 2
5 flageolets Flageolet 3/4" 1500# RF 3/4" Pc 1
6 Ball Valve Ball valve, Flanged. RF , RB , CS 3/4" x1500# 3/4" Pc 1
7 Gasket Gasket SW. Graph. Fill , CR , 1500# 3/4" Pc 1
8 Bolts Stud Bolts with Nuts for 3/4" x 1500# 3/4" Pc 4
Option 3 ( Bypass removal )

1 Pipe Pipe CS , ASTM A-106 GrB ,. Sch-160 16” M 3
2 Pipe Pipe, CS API 5LX65 , WT 11.91mm 16” M 1
6. Conclusion:
 Execution of the first option requires a big installation of piping and

PSV, so that a considerable budget should be allocated, on the other hand,
this option will definitely eliminate potential risk of high pressure.
 Execution of the second option will mitigate potential risk of high
pressure as there will be two isolation valves (new XV and 200-XV-2001),
on the other hand, budget of this option will be lower than the first one.
 Finally, if a decision is taken that there is no more need for bypass line,
the potential risk will be disappeared if the bypass line is removed.
Page 8 of 9
7. Attachments:
 P&ID Drawing No. (200-EPR-PID-03061-001 Proposal #1)

 P&ID Drawing No. (200-EPR-PID-03061-001 Proposal #2)
Page 9 of 9

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PROJECT : AL-SHAER GGS REHABILITATION PROJECT

Ebla Petroleum Company - EBCO

ASAS Contracting Ltd.

00 05-08-2018 ISSUED FOR REVIEW AK HK/OHU Z.R

3.1. First Proposal 4

3.2. Second Proposal 4

3.3. Third Proposal 4

4.1. PSV Installation on Bypass Line 4

4.2. Additional XV installation D/S the Existing 200- XV-2001 5

4.3. Removal of bypass line 5

ASAS started an integrated technical study of the project, followed by a HAZOP

3.1. First Proposal:

3.2. Second Proposal:

3.3. Third Proposal:

4.1. PSV Installation on Bypass Line:

PSV Installation Scope Of work will include but not limited:

4.2. Additional XV installation D/S the Existing 200- XV-2001:

Additional isolation Valve Scope of work will include but limited:

4.3. Removal of bypass line:

The mechanical activities to remove the existing 8” Inlet Manifold Bypass

Shaer GGS - Bypass Safeguarding options - HAZOP Action

Option 1 ( PSV Installation )

Option 2 ( MTO for Additional XV , 8" 1500# )

Option 3 ( Bypass removal )

 Execution of the first option requires a big installation of piping and

 P&ID Drawing No. (200-EPR-PID-03061-001 Proposal #1)

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