Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

0001 00

A2

Sh. 1 of 12

WAFA PLANT
SPARING AND STAND BY
PHILOSOPHY REPORT

A2

03/07/00

ISSUED FOR APPROVAL

A1

19/06/00

ISSUED FOR APPROVAL

P1

28/12/1999

REV.

DATE (DD/MM/YY)

T. MILETIC

M. RICCI

COLANERI/E. BARONE

KASHIM

T. MILETIC

M. RICCI

COLANERI/E. BARONE

KASHIM

L. CONA

M. RICCI

COLANERI/E. BARONE

WRITTEN BY

VERIFIED BY

APPR./AUTH. BY

ISSUED FOR COMMENTS

W - Mod. 1809/E TYPE A - Rev. A

STATUS

AGIP GAS B.V.

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

0001 00

Sh. 2 of 12

INDEX
1.

SCOPE

2.

OVERALL SYSTEM AVAILABILITY TARGET

3.

GENERAL CRITERIA

4.

PROCESS UNITS - DETAILED DESCRIPTION

4.1.

Unit 300 : Gas Inlet Reception Facilities

4.2.

Unit 310 : Gas dehydration

4.3.

Unit 330 : Gas Sweetening

4.4.

Unit 340 : Gas Dew Point Control

4.5.

Unit 350 : Gas demercurization (space allocation for possible future installation).

4.6.

Unit 360 : Inlet gas compression

4.7.

Unit 361 : Off Gas Compression

4.8.

Unit 362 : Export gas compression

4.9.

Unit 200 : Inlet Oil Reception Facilities

4.10.

Unit 210 : Liquid Stabilization

4.11.

Unit 220 : Condensate Storage

4.12.

Export Gas Pipeline

4.13.

Export Oil Pipeline

5.

UTILITIES - DETAILED DESCRIPTION

5.1.

Unit 230 : Flare Systems

5.2.

Unit 240 : Burn Pit

5.3.

Unit 410 : Hot Oil System

5.4.

Unit 420 : Fuel Gas System

5.5.

Unit 430 : Diesel Oil System

5.6.

Unit 460 : Air System

5.7.

Unit 470 : Main Power Generation

5.8.

Unit 480 : Emergency Diesel Generators

5.9.

Unit 520 : Cooling Water System

5.10.

Unit 530 : Fresh Water Treatment

5.11.

Unit 540 : Open Drain System

5.12.

Unit 540 : Closed Drain System

5.13.

Unit 600 : Nitrogen System

W - Mod. 1810/E TYPE A - Rev. A

A2

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

5.14.

Unit 620 : Steam Out System

5.15.

Unit 730 : Fire Water System

W - Mod. 1810/E TYPE A - Rev. A

0001 00

A2

Sh. 3 of 12

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

1.

0001 00

A2

Sh. 4 of 12

SCOPE
The scope of this report is to outline the sparing and stand by philosophy which will be
followed during the development of the basic design of the WAFA Desert Plant &
Utilities.

2.

OVERALL SYSTEM AVAILABILITY TARGET

The availability target is to achieve:
-

Maximum allowed yearly downtime for WAFA Desert Plant, equal to 28 days at
50 % gas production rate.
It includes unexpected downtime period and scheduled downtime period (for
routine maintenance and major overhaul). Said target is to be considered a
maximum figure and it is not expected every year.
Allowed total yearly shutdown equal to 0.5 %; it means that the total gas
production at Wafa desert can be zero (due to a unscheduled shut-down) only for
less than 0.5 % of the yearly time (i.e. 43.8 hours);

To reach the abovesaid target the basic philosophy that will be applied is to split the oil
separation/treatment plant and the gas separation/treatment plant into two parallel
trains sized at 50% capacity each.
Exceptions to this philosophy will be taken in some places where single equipment will
be spared (see paragraph 4), but keeping the general concept that 50 % of production
has to be maintained.
This is considered to satisfy the max yearly shutdown target because:
a)
b)

the probability of two parallel lines shut down at the same time for accidental
reasons is extremely low;
in case one line is in major overhaul, the other line could be affected only by
small emergency situations which can be solved in short time, enabling said line
to restart well before the period of 43.8 h. In fact all items more likely subject of
failures, such as rotary equipment, will be spared adequately. Failure of static
equipment is not considered.

The target of max total yearly downtime at 50 % capacity is considered reached since
it is possible to operate maintenance on one train keeping half of the plant production.
For sure this will require a careful planning of the maintenance.
The consequence of the required availability target on utilities units is that:
the global availability for all utility facilities directly linked to plant production, such
as Flare, Fuel Gas, Power Generation, Instrument Air, Cooling Water, Steam &
Condensate and Fresh Water Treatment Systems shall be at least as high as
that of process units (>99.5%);
some utilities (HP flare) shall be split into two systems, each one dedicated to
one Process train;

W - Mod. 1810/E TYPE A - Rev. A

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

3.

0001 00

A2

Sh. 5 of 12

even if utility distribution is common to process trains, an adequate sparing of

equipment and control valves shall be foreseen in order to ensure at least half of
the production practically 100 % of the time.

GENERAL CRITERIA
Within each line, stand-by equipment will be provided for items which need frequent
maintenance or load sharing (e.g. filters, pumps), whenever necesary to ensure the
required quality and continuity.
Availability of spare parts, or of a complete equipment, in maintenance warehouse has
been considered, case by case.
Here below is the general sparing philosophy per type of equipment for WAFA Desert
Plant (Process & Utilities Units). Exceptions and particularities to the above sparing
philosophy for units, machines and packages are indicated in the following paragraphs
PROCESS UNITS and UTILITY UNITS.
Filters

2 x 100%

Storage tanks

2 x 50%

Chemicals tanks

1 x 100%

Drums & Columns

1 x 100%

Compressors

See 4

Pumps:
- Continuous service

2 x 100%

- Intermittent service

3 x 50%
1 x 100%

Air coolers:
- Number
- Number of fans

1 x 100%
2 per bay min

Safety Valves

N+1

W - Mod. 1810/E TYPE A - Rev. A

(allows cleaning or repairing

of leaks on one tank)

when serving one process

train
when serving 2 process trains

N when installation speared

equipment and for thermal
relief

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

4.

0001 00

A2

Sh. 6 of 12

PROCESS UNITS - DETAILED DESCRIPTION

Within these plants the criterion shown above of inserting sparing and stand-by
equipment has been adopted with the aim of keeping the required continuity level of
the production.

4.1.

Unit 300 : Gas Inlet Reception Facilities

The section is based on two parallel lines at 50 % capacity.

4.2.

Unit 310 : Gas dehydration

The section is based on two parallel lines at 50 % capacity.

4.3.

Unit 330 : Gas Sweetening

The section is based on two parallel trains at 50 % capacity, except the fresh amine
preparation facilities, which are common.

4.4.

Unit 340 : Gas Dew Point Control

The section is based on two parallel lines at 50 % capacity.
In consideration of its high reliability and high cost, the complex
turboexpander/compressor has not been spared. However 2 valves in parallel each
sized for 100% capacity are provided to operate the unit in Joule Thompson mode. In
this condition the gas production is anyhow assured.

4.5.

Unit 350 : Gas demercurization (space allocation for possible future installation).
The section is based on two parallel lines at 50 % capacity.

4.6.

Unit 360 : Inlet gas compression

The section includes four complete compression lines, each one sized for 33% of total
gas capacity, three normally operating and one common spare.

W - Mod. 1810/E TYPE A - Rev. A

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

4.7.

0001 00

A2

Sh. 7 of 12

Unit 361 : Off Gas Compression

This section includes two complete compression lines, each sized for 100% gas flow
rate, and normally operating and one spare.

4.8.

Unit 362 : Export gas compression

The section includes three complete compression lines, each one sized for 50 %
capacity, allowing 100 % flow rate of the export gas, even in case one line is out of
service.

4.9.

Unit 200 : Inlet Oil Reception Facilities

The section is based on two parallel lines at 50% capacity.

4.10.

Unit 210 : Liquid Stabilization

This section is based on the two train philosophy each sized for 50% capacity, where
only desalters are single line.
Desalters are not spared since the desalting section includes two desalters connected
in series and ancillary equipment.
It is necessary to underline that desalters have a very high reliability and that, in case
one of said desalters is out of service, the remaining one can give the same
performance, without capacity or quality decrease.
As a consequence, when one of the desalters is out of service the only disadvantage is
an increase of fresh water consumption. The design of the water system shall be
developed in consideration of this possible situation.

4.11.

Unit 220 : Condensate Storage

The unit includes no. 2 storage tanks.
The booster pumps and the liquid export pumps are three items each. At maximum
capacity two are operating and one is common spare.

4.12.

Export Gas Pipeline

The pipeline status will be monitored with intelligent pigging once every three years,
approximately.
During the pigging operation the pipeline flow will be reduced because the operation
will be made at a velocity of 2 m/s (versus 10 m/s normal operating velocity) and, as a
consequence, the pipeline capacity will be reduced to 20 %.
This operation will take 4 days (three of effective pig travel and one day for launching,
receiving and replacing the pig itself).
This operation is, theoretically, in conflict with the requirements because for at least 4
days (in three years) the plant will run at a capacity lower than 50 %.
However, no spare will be provided for the gas pipeline due to the high investment cost
involved.

W - Mod. 1810/E TYPE A - Rev. A

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

4.13.

0001 00

A2

Sh. 8 of 12

Export Oil Pipeline

The status of this pipeline too will be monitored with intelligent pigging once every
three years, approximately.
During the pigging operation the pipeline flow will be only slightly reduced, mainly
because the operation will be made at a velocity of 2 m/s, very near to operating
velocity. This operation will take 4 days (three of effective pig travel and one day for
launching, receiving and replacing the pig itself).
This operation will comply with the requirements because in the 4 days (in three years)
when the pigging will be performed, the plant will run at a near to design capacity
No spare will be provided for oil pipeline.

5.

UTILITIES - DETAILED DESCRIPTION

5.1.

Unit 230 : Flare Systems

The need for replacement of one HP or LP flare tip if it has been burnt down is not
unlikely. Therefore, two flare stacks are provided.
Flare System is composed of the following equipment: one HP flare Header, one
Dry/Cold Flare Header, one HP flare KO drum, one Dry/Cold flare KO drum, two
interlocked HP Flare risers and two HP flare tips, each one designed for 100%.
Dry/Cold flare riser joins HP flare riser upstream flare stacks.
LP Flare System is composed of the following equipment: one LP Flare Header, one
Acid Flare Header, one LP Flare KO Drum, two interlocked LP Flare risers and two LP
Flare tips, each one designed for 100%.
Flare stacks are located so that each one is not affected by radiations from the other.
Sparing philosophy is the following:
Flare KO drum Pumps
Ignition panel
Flare pilots

5.2.

2 x 100% per drum

1 per Flare stack
3 per Flare stack

Unit 240 : Burn Pit

Burn Pit operation is intermittent and not directly linked to the production, so no sparing
is necessary.
Burn Pit
Burn Pit Drum
Burn Pit Pump

5.3.

Unit 410 : Hot Oil System

W - Mod. 1810/E TYPE A - Rev. A

1 x 100%
1 x 100%
1 x 100% + one in warehouse.

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

0001 00

A2

Sh. 9 of 12

Sparing philosophy is the following:

Hot Oil Storage Tank
Hot Oil Drain Drum
Hot Oil Feed Pump
Hot Oil Feed Filter
Hot Oil Side Stream Filter
Hot Oil Expansion Drum
Hot Oil Circulation Pumps
DEA Reboilers Heating Circuit Pumps
Hot Oil Air Cooler
WHRUs
WHRUs recirculation pumps

5.4.

1 x 100%
1 x 100%
1 x 100% + 1 in maintenance warehouse
1 x 100%
1 x 100%
1 x 100%
3 x 50%
2 x 100% per heater
1 x 100%
3 x 100%
2 x 100% per WHRU.

Unit 420 : Fuel Gas System

Fuel Gas availability is of a critical importance for production continuity. Any Fuel Gas
System shut down would imply a total production shut down for at least a few hours.
Therefore high Fuel Gas system reliability and availability is required. Having two Fuel
gas packages, each one designed at 100% and constituting a separate fire zone,
working in parallel in normal operation, is the most reliable solution with not excessive
additional cost. If a failure occurs on one package, the pressure control of the second
one allows to maintaining the whole fuel gas duty. Moreover, no sparing of control
valves, or fuel gas heaters inside each fuel gas package is necessary. The sparing
philosophy is then the following:
Fuel Gas Packages
Fuel Gas Drums
Pressure Control Valves
HP Fuel Gas Heater
LP Fuel Gas Heater
HP Fuel Gas Filters

5.5.

2 x 100%
1 x 100% per package
1 x 100% per package
1 electric (start-up) per package
1 Hot Oil per package
2 x 100% per package

Unit 430 : Diesel Oil System

Diesel oil storage capacity is designed for 7 days of Emergency Diesel Generators
consumption (WAFA Plant and Logistic area). Normally no maintenance is necessary
on diesel oil storage tank. If it were the case, diesel oil could be supplied directly from
tank trucks. Sparing philosophy is the following:
Diesel Oil Storage Tank
Diesel Oil unloading pump
Diesel Oil Pumps
Diesel Oil Station
Diesel Oil Filters

W - Mod. 1810/E TYPE A - Rev. A

1 x 100%
1 x 100%
2 x 100%
1 x 100%
2 x 100%

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

5.6.

0001 00

A2

Sh. 10 of 12

Unit 460 : Air System

Instrument Air is a critical utility for the plant operation. No failure, neither in Instrument
Air flow rate (pressure), nor Instrument Air quality (water dew point) is acceptable. That
is why one main spare Air Screw Compressor (in maintenance every 2,000 h) and two
Start-up Air Screw Compressors (each one designed for half of one Main Air
Compressor duty), and one stand-by Air Treatment package are necessary. Indeed, it
is not unlikely that regeneration sequence of cold regenerated absorption type air
dryers could be out of order. Therefore, sparing philosophy is the following:
Main Air Screw Compressors
Start-up Air Screw Cmpressors
Air Treatment Packages
Wet Air Receiver
Instrument Air Receivers

5.7.

4 x 33%
2 x 50%
2 x 100%
1 x 100%
2 x 50%

Unit 470 : Main Power Generation

Main power generation being essential for the plant operation, a high reliability and
availability level of Main Power Generation System is required. This can be achieved if
the following conditions are respected:
-

The type of turbines is homogeneous with the ones used for turbo-compressors
(FRAME 5), in order to standardise spare pieces of equipment and maintenance
procedures.
The number of turbo-generators in normal operation allows that if one turbogenerator trips, the remaining one could take the whole electric power and waste
heat recovery duties instantly.
There is always one turbo-generator in stand-by for eventual maintenance
purposes (turbines, electric generators or waste heat recovery units).

Sparing philosophy is then the following:

Turbo-generators
Fuel Gas Separators
On line/Off line washing water skids
5.8.

Unit 480 : Emergency Diesel Generators

Emergency Diesel Generators
Diesel Oil daily tanks

5.9.

3 x 100%
1 per Turbo-generator
1 for all Turbo-generators

2 x 100%
1 per EDG (sized for 12 hours min)

Unit 520 : Cooling Water System

Sparing philosophy is the following:
Cooling Tower
Number of Cells
Pumps

W - Mod. 1810/E TYPE A - Rev. A

1 x 100%
1 + 1 (allows maintenance and cleaning)
3 x 50%

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

5.10.

0001 00

A2

Sh. 11 of 12

Unit 530 : Fresh Water Treatment

Total storage capacities for the different fresh waters of WAFA Desert Plant are
designed for the following consumption periods:
Winning water
Desalinated water
Demineralized water
Potable water

3 days consumption + 10 hours of fire fighting water

3 days + 7 days of extra desalinated water needed while
one Desalter is in maintenance
3 days
3 days + half of Strip Area fire Water Storage Capacity

These storage capacities are essential for pumping in series operation and represent
safety hold-ups in order to cope with exceptional events and give higher reliability and
flexibility of operation of the whole water treatment chain. Each storage capacity is split
into two tanks in order to allow an intervention on tanks for cleaning or leak repairing,
without need of water treatment shut down, and consequently production shut down.
Sparing philosophy is the following:
Winning Water Well Pumps
Winning Water Sand Filters
Storage Tanks
Pumps
Chemical Storage Tanks
Chemical Injection Pumps
Water Desalination packages
Water Demineralisation packages
Mixed Bed Exchangers
Potable Water Pressure Vessel
Potable Water Active Carbon filters

5.11.

Unit 540 : Open Drain System

Open Drain Drum
Open Drain Pumps

5.12.

Company responsibility
2 x 100%
2 x 100%
2 x 100%
1 x 100%
2 x 100%
2 x 100%
1 x 100%
2 x 100%
1 x 100%
2 x 100%

1 x 100%
1 x 100% + one in maintenance warehouse

Unit 540 : Closed Drain System

Two closed hydrocarbon drain systems will be envisaged: one cold and one wet.
Number of drain collecting vessels required for each system will be finalized according
to the plot plan definition
Closed Drain Drums
Closed Drain Pumps

W - Mod. 1810/E TYPE A - Rev. A

one per Area A1, B1, C1, D1, E1, L1, F1, N1
1 x 100% par each Closed Drain drum + one in
maintenance warehouse

Originator

Module

53

Type

Discipline

Identification N

Rev.

LIBYAN BRANCH

Contract N 0001GP99

WESTERN LIBYA GAS PROJECT

TPIT Project N 1989

AGIP GAS BV LIBYAN BRANCH

5.13.

0001 00

A2

Sh. 12 of 12

Unit 600 : Nitrogen System

Cryogenic nitrogen generation is used, instead of membranes, because great
quantities of liquid nitrogen are necessary for maintenance purposes. This unit needs
periodic defrosting and maintenance operations, so that liquefied nitrogen capacity is
sized to provide nitrogen needs during this period.
Sparing Philosophy is the following:
Refrigeration Units
Molecular Sieves
Cold Box
Expansion Turbines
Cryogenic Nitrogen Storage Drums
Finned Tube Banks
Electric Tank Heaters

5.14.

2 x 100%
2 x 100%
1 x 100%
2 x100%
2 x 50% or 3 x 33%
N+1
2 x 100%

Unit 620 : Steam Out System

Steam Out System is used only for maintenance purposes, so no sparing is foreseen.

5.15.

Unit 730 : Fire Water System

Sparing philosophy is the following:
Jockey pumps
Diesel Fire Water pumps
Diesel Oil daily tanks
Electric fire Water pump

W - Mod. 1810/E TYPE A - Rev. A

2 x 100%
2 x 100%
1 per Diesel Fire Water pump (sized for 12 hours min.)
1 x 100%