WAHA OIL COMPANY

FAREGH FIELD DEVELOPMENT PHASE 2

TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 2 of 18

CONTENTS PAGE NO.

1.0 INTRODUCTION 3

2.0 OVERVIEW OF PROCESSING FACILITIES 4

2.1 Gas Processing Facilities 4

2.2 Condensate Processing Facilities 5

3.0 OPERATING PHILOSOPHY 6

3.1 Production Strategy 6

3.2 Plant Turndown 6
3.3 Slug Handling 6
3.4 Flowline Pigging 6
3.5 Automatic Well Testing 6
3.6 Re-Processing of Off-Specification Condensate 6
3.7 Gas Train - Parallel Heat Exchanger Operating Mode 7
3.8 Auto Start Pumps 7
3.9 Nitrogen 7
3.10 Flare Systems and Burn Pit 7
3.11 Fuel Gas Systems 8
3.12 Chemicals 8

4.0 CONTROL PHILOSOPHY 10

4.1 General 10
4.2 Wellhead Facilities 10
4.3 Gas Processing 10
4.4 Condensate Processing 14
4.5 Utility Systems 17

5.0 WAHA CENTRAL INTERFACE 18

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 3 of 18

1.0 INTRODUCTION

This document describes in general terms the operating and control philosophy for the
process and utility systems for the facilities at the WAHA Faregh Field (Phase 2) Gas
Plant in Libya.

The Faregh Phase 2 Gas Plant facilities consist of:

• Gas gathering initially from eight wells, increasing to a maximum of forty five wells
in the future
• Gas/Liquid separation and gas conditioning
• Export Gas compression
• Phase 2 gas metering into the Faregh Phase 1 gas pipeline to Zuetina
• Condensate stabilisation
• Condensate metering and export through the crude oil pipeline to Gialo
• Utility systems, i.e. Flare system, Instrument Air system etc.
• Fire Water System
• Recycle Gas Compression
• Well Testing
• Fuel Gas System
• Gas Dehydration Unit
• Chemicals- Corrosion Inhibitor, Methanol, etc

The Emergency Shutdown considerations are addressed in the latest revision of the
Emergency Shutdown (ESD) Philosophy, document number 5906G-GL-P-RP-2007 00.

Process Design Criteria is addressed in the latest revision of document number 5906G-
GL-P-RP-2005 00

The Flare and Venting system design philosophy is addressed in the latest revision of the
Process Flare, Vent and Relief Philosophy, document number 5906G-GL-P-RP-2008 00.

For design basis information refer to the latest revision of the ‘Basis of Design’ document
number 5906G-GL-P-GE-2010 00

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 4 of 18

2.0 OVERVIEW OF PROCESSING FACILITIES

2.1 Gas Processing Facilities

Gas from the production wells will flow to the Faregh Phase 2 Gas Plant via dedicated
buried and lined flowlines. Gas from these flowlines will be received at the Plant Inlet
Manifold (L-511 A/B). Under normal operation the gas will be collected in a common
production header and routed to the Slug Catcher (C-731). Gas from individual wells
may also be routed via a common Test Header to the Test Separator (C-531).

The Slug Catcher will be a pipe array type separator, designed to accommodate the
maximum anticipated slug volumes. It will also provide liquid condensate hold up for up
to 2 hours if the condensate stabilisation system goes off specification and is operated at
reduced throughput. The Slug Catcher will be designed for flowline design pressure.

Liquid hydrocarbons will be routed from the Slug Catcher under flow control, reset by
level, to the condensate stabilisation facilities.

Water from the Slug Catcher will be routed under interface level control to the Water
Degassing Drum (C-811), which operates against LP Flare back pressure. Water from
the Water Degassing Drum will be drained under level control to the Faregh Phase 1
Processing Plant water disposal facilities.

Gas from the Slug Catcher will feed a single gas processing train designed to produce
180MMSCFD for export. The gas train will consist of:

• Gas dehydration facilities

• Hydrocarbon dewpointing facilities
• Export gas compression and metering

The gas dehydration facilities will consist of a Glycol Contactor, which reduces the water
content of the process gas to meet the downstream processing requirements/export gas
specification. Glycol regeneration facilities are also included.

The hydrocarbon dewpointing facilities will consist of the Propane Refrigeration Package
(T-60), which cools the process gas to meet the export gas hydrocarbon dewpoint
specification.

Gas from the dehydration and dewpointing facilities will be compressed and metered
before entering the gas transmission pipeline.

Note that upstream of the gas processing train, the Inlet Manifold and Slug Catcher are
designed to handle an additional 60 MMSCFD which, if produced, will be routed via a
cross-over line, on flow control, to the Phase 1 HP Separator. This is to make use of the
spare capacity within the Phase 1 processing train.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 5 of 18

2.2 Condensate Processing Facilities

The condensate stabilisation facilities will consist of:

• Stabiliser Feed Drum (C-641)

• Stabiliser Column (C-651)
• Stabiliser Reboiler (F-651)
• Stabiliser Reboiler Pump (G-651 A/B)
• Stabiliser Feed/Bottoms Exchanger (E-651)
• Condensate Rundown Cooler (E-652)
• Recycle Gas Compression
• Condensate Export Pumps (G-761 A/B/C) and Metering

These facilities will be designed to process raw condensate from the Slug Catcher and
from the Gas Dewpointing Train to achieve the required export condensate Reid Vapour
Pressure (RVP) specification.

The Stabiliser Feed Drum flashes condensate from the Slug Catcher, Dehydration and
Gas Dewpointing facilities. Flash gas under pressure control flows to the suction of the
Recycle Gas Compressors (K-661 A/B/C). Condensate flows to the Stabiliser Column,
75% under flow control via the Feed Bottoms Exchanger to tray 6 and 25% direct to the
top tray under flow control. Water is routed, under interface level control to the Water
Degassing Drum.

The Condensate Stabiliser column stabilises the liquid feed from the Stabiliser Feed
Drum to the required RVP specification. Stabilised condensate is routed through the
Feed Bottoms Exchanger and Rundown Cooler and pumped through the condensate
metering directly to the existing Faregh Phase 1 crude export line by the Condensate
Export Pumps, under level control.

For operational flexibility, condensate can also be pumped to Phase 1 Wash Tank via the
off specification routing

On detection of off-specification condensate, the condensate export route is switched

from the metering skid to the Phase 1 Wash Tank via the HP and LP Flare KO Drums. In
addition to the hold up capacity provided in the Phase 1 Wash Tank the Slug Catcher is
designed to accommodate 2 hours condensate at design throughput over and above the
slug handling capacity.

Gas from the overhead of the Stabiliser Column is routed under pressure control and is
combined with gas from the Stabiliser Feed Drum, compressed by the Recycle Gas
Compressor and returned to the inlet of the gas dehydration facilities.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 6 of 18

3.0 OPERATING PHILOSOPHY

3.1 Production Strategy

The first priority for operation of the Faregh Phase 2 Gas Plant is to produce the
180MMSCFD of export gas meeting the required specification with minimal Gas flaring,
HC liquid burning and minimal Plant downtime without compromising the safety of
personnel, the integrity of equipment and the environment.

3.2 Plant Turndown

The plant is designed for turndown to 50% capacity (90MMSCFD of treated gas).

In normal operation throughput reduction will be achieved by the progressive shutdown of

wells, either manually at the inlet manifold (by valve closure), or by automatic shutdown
at the wellhead on over pressure protection trips. Where sustained throughputs below
60% of design are required, the Export Gas Compressors K-621 A/B/C (configured as 3 x
60%) control system is such that it will allow the two normally operating compressors to
remain running all the time.

3.3 Slug Handling

The plant will be operated to maintain a minimum liquid level in the Slug Catcher at all
times except on receipt of a large slug and when condensate is being held up to minimise
production of off specification condensate product.

3.4 Flowline Pigging

There is no regular pigging planned and as a result any pigging operations will require
temporary pig launching and receiving facilities to be installed. Valved Connections will
be provided at the wellheads and at the plant reception facilities for this purpose. Note
that the flowlines are internally coated, with indented joining sleeves at every pipe section
join, and therefore the pigs used should be of the non-rigid type (soft pigs).

3.5 Automatic Well Testing

Facilities are provided to allow remote testing of each well at the Faregh facilities from
either the CCS or Waha Central.

3.6 Re-Processing of Off-Specification Condensate

No provision is made to re-process off specification condensate: all off specification

product is routed to the Phase 1 Wash Tank via the HP and LP Flare KO Drums.
However, the stabilisation system is designed to allow liquids held up in the Slug Catcher
to be processed on top of the normal continuous liquid rate.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 7 of 18

3.7 Gas Train - Parallel Heat Exchanger Operating Mode

Once reliable operating experience has been gained and proven with the normal
operating arrangement of the gas cooling exchangers, the gas exchanger configuration
may be changed to the alternative parallel operating mode. This will allow the Warm
Separator to be operated at reduced temperatures should it be found that there are no
problems associated with wax formation. In the alternative parallel mode, the normal flow
path is blocked off and piping/valves arranged to operate the First Gas/Gas Exchanger
(E-551), the Second Gas/Gas Exchanger (E-571) and the Gas/Liquid Exchanger (E-591)
in parallel operation upstream of the Warm Separator (C-581). Cold gas from the
Refrigeration unit is routed to the shell side of E-551 and E-571 in parallel.

3.8 Auto Start Pumps

Where an auto start facility is provided on process pumps to minimise process upsets
following pump trips, the operator must ensure that the spare pump is lined up, i.e.
suction and discharge valves open, pump primed and automatic mode selected.

3.9 Nitrogen

There are no plant facilities to produce nitrogen. Nitrogen requirements for purging and
any other uses that may be required will be evaluated during detailed engineering.

Nitrogen required for purging of facilities and other plant uses will be supplied from
bottled storage as deemed necessary.

3.10 Flare Systems and Burn Pit

Two flare systems are proposed. An HP flare system including cold and warm headers
to cater for the flaring requirements of the process unit and a LP flare system to cater for
gas from the low pressure sources such as the glycol package reboiler.

High high level in the HP Flare KO Drum (C-691) or the LP Flare KO Drum (C-841) will
initiate the shutdown of the process systems.

Continuous fuel gas purging of the flare headers is provided to avoid air ingress.

A Burn Pit is provided for the disposal of waste liquid hydrocarbons. Waste
hydrocarbons may be routed to the Burn Pit, if required, under level control from either,
the Closed Drains Drum, the HP Flare KO Drum or the LP Flare KO Drum. It is
anticipated that under normal operation, all liquid hydrocarbons collected in the HP Flare
KO Drum are pumped to the LP Flare KO Drum. Liquids from the LP Flare KO Drum or
the Closed Drains Drum will be routed to the Phase 1 wash tank.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 8 of 18

3.11 Fuel Gas Systems

Two fuel gas systems are envisaged: HP and LP. The HP fuel gas system is used to
supply the gas turbine drivers and the LP fuel gas is used for purging, pilot gas, fired
heater fuel and blanketing operations.

Continuous supply to the HP fuel gas system is from the gas outlet of the Warm
Separator operating at 396psia and an alternative source will be supplied from the export
gas compressor suction header operating at 318psia. Two additional alternate sources
are also provided for the HP fuel gas system from the Zeutina gas pipeline and also from
within phase 2, downstream of the export gas metering package. These sources operate
at about 1000psia and metering is provided to measure the gas buy-back from within
phase 2.

The supply from the Zeutina pipeline can be utilised during start-up when there is no gas
available from Phase 2. The dual provision from within Phase 2 and Zeutina pipeline
respectively, can also be utilised whenever a higher gas pressure is required than what
is available from the warm separator/ export gas suction header sources. These
alternative sources will be utilised at the discretion of the operator. The level of flexibility
inherent in this design will ensure that HP fuel gas can be made available to the Phase 2
users at all times. Gas feed to the HP fuel gas system from all the sources are pressure
controlled and the set points of the controllers can be adjusted to satisfy the pressure
requirements of the equipment utilizing the HP fuel gas.

Continuous LP fuel gas is supplied from the overhead of the Stabiliser Feed Drum
operating at 170psia while back-up LP fuel gas is provided by a cross-over line from the
HP fuel gas system. Gas from both sources are pressure controlled and the set points of
the controllers can be adjusted to satisfy the requirements of the equipment utilizing the
LP fuel gas.

For increased system reliability, dual pressure control valves will be provided at the inlets
of the continuous sources for both the HP and LP fuel gas systems. Both control valves
will operate simultaneously sharing 50% of the duty.

A fuel gas heater will be provided to temperature condition the HP fuel gas to meet the
specific user requirements. Any further HP fuel gas conditioning required, such as
filtration, will be provided at the user by each vendor.

LP fuel gas will be used for blanketing the vapour space of vessels, drums and tanks,
where necessary.

3.12 Chemicals

Wellhead methanol injection rates required for cold start up and other uses will be
specified by the engineer and supplied by others.

Methanol may be injected into the gas stream between the vapour outlet of the Slug
Catcher C-731, upstream of the control valve located downstream of LTS in Propane
Refrigeration Unit and the control valve FV7301 from a methanol storage / injection
package. Other locations for methanol injection will be identified during basic engineering
design and confirmed during detailed engineering.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 9 of 18

Continuous corrosion inhibitor injection at the gas wellheads is not required. The
flowlines will be internally coated for corrosion resistance.

On plot injection of corrosion inhibitor chemicals will be supplied via dedicated

injection/dosing packages complete with storage vessels.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 10 of 18

4.0 CONTROL PHILOSOPHY

4.1 General

The objective of the control system for the Faregh Phase 2 Gas Plant will be to maintain
steady state conditions, and to automatically compensate for upsets in the gas
processing and condensate processing facilities so as to achieve the export gas and
stabilised condensate specifications over the flow and operating range of the plant.

The Faregh Phase 2 facilities will be monitored and controlled from the Central Control
System (CCS), which will interface with the individual packaged equipment controls as
well as provide recording of plant operational data.

Refer to the Process Flow Diagrams and the Piping and Instrument Diagrams for plant
control scheme.

4.2 Wellhead Facilities

Each well head will be provided with equipment which is controlled locally. There is no
control link to the CCS from the production wellheads.

4.3 Gas Processing

4.3.1 Overall Flow Control Philosophy

The overall control of Faregh Phase 2 facilities are set to operate as follows:

Gas flow through the Faregh Phase 2 Gas Plant will initially be set up by manual
adjustment of the wellhead choke valves. The downstream backpressure of these choke
valves will be adjusted to provide a maximum inlet pressure of 452psia at the Plant inlet
manifold(please refer to tables 2.1 through 2.6 of the latest revision of the Flowline
Hydraulic Analysis Report Doc. # 5906G-GL-L-RP-4004 00).

At the Slug Catcher, the gas outlet stream is flow controlled reset by pressure and the
condensate outlet stream is flow controlled reset by the liquid level between the vessel
normal and high liquid levels.

In addition, upstream of the Slug Catcher gas outlet flow control valve is a cross-over line
to Phase 1. The Inlet Manifold and Slug Catcher are designed to handle an additional 60
MMSCFD which, if produced, will be routed via this cross-over line, under flow control, to
the Phase 1 HP Separator.

The Slug Catcher has a total liquid hold-up capacity of 1841bbl.This is made up of 365bbl
for the estimated largest liquid slug and 1476bbl for estimated two hours hold-up of
liquids at the plant rated capacity.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 11 of 18

In normal operation, turndown / throughput reduction will be achieved as follows. The

pressure control valve on the Slug Catcher gas outlet, controlled on downstream
pressure, will close and limit the maximum pressure in the downstream gas processing
train. The Slug Catcher is designed for the flowline design pressure. This allows the
pressure to build up in the Slug Catcher and the flowlines until the flowrate into the plant
is reduced to match the gas plant throughput by the progressive shutdown of wells by
automatic shutdown at the wellhead on over pressure protection trips.

Plant operations personnel can also reduce plant throughput by the manual closure of
the flowline isolation valves, at the production manifold. Closure of a flowline isolation
valve will result in automatic shutdown at the wellhead on the over pressure protection
trip.

4.3.2 Pressure Control

Slug Catcher operating pressure (plant arrival pressure) will be controlled by a pressure
controller, overhead of the Slug Catcher, which provides the set point to a flow controller
acting on a flow control valve located on the Slug Catcher overhead line.

Gas processing train operations (dehydration and gas dewpointing) will be pressure
controlled, by a pressure controller located downstream of the Slug Catcher overhead
gas outlet flow control valve, to ensure gas conditioning operations are maintained at a
fixed pressure. The gas processing train operating pressure will be controlled, across the
majority of gas processing rates, at the Export Gas Compressor Suction, by varying
Export Gas Compressor turbine speed.

If the plant gas arrival rate decreases, the compressor turbine speed is reduced to
maintain gas processing train operating pressure. At turbine minimum speed further
throughput reduction is achieved by compressor suction throttling. Compressor suction
throttling will be controlled to maintain gas processing train operations at the required
operating pressure by a pressure controller located overhead of the Cold Separator
acting on a downstream pressure control valve. If gas arrival rate reduces to a rate
below the minimum capacity of the Export Gas Compressor an anti-surge recycle valve
will spill back export gas to maintain compressor throughput.
Note, it may be that individual suction throttling will be provided for each compressor,
depending on compressor operating configuration / vendor information, to allow two
compressors to remain running at all times at plant throughputs less than 60% turndown.

If the plant gas arrival rate increases, the compressor turbine speed is increased to
maintain gas processing train operating pressure. At maximum turbine speed gas train
operating pressure is controlled by a downstream pressure controller acting on the
pressure control valve, located overhead of the Slug Catcher. As the gas processing
train pressure rises the pressure controller throttles back the feed gas to maintain
operating pressure. As a result of this throttling, pressure will rise in the Slug Catcher
and flowlines. In the event that steps are not taken to either increase the plant
processing capacity, e.g. run more export gas compressors, or close down production
wells, back pressure at the wells will continue to rise until sufficient wells have been
tripped, by the high pressure trips located at each wellhead, to match gas production rate
to plant gas processing capacity

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 12 of 18

The Test Separator is pressure controlled by a split range controller. The Test Separator
gas is normally routed to the inlet of the Gas Dehydration unit and any over pressure is
spilled off to the HP flare system.

4.3.3 Glycol Dehydration

Refer to vendor documentation for the operating and control philosophy for the Glycol
Dehydration Package.

4.3.4 Propane Refrigeration

The Propane Refrigeration Package operating pressure will be maintained at a fixed
value. For details of the operating and control philosophy for the Propane Refrigeration
Package refer to supplier documentation.

A shut down of the Refrigeration unit will trigger a level 3 shut down which will shut down
the phase 2 gas plant(please refer to the latest revisions of the Process Cause & Effects
Doc.# 5906G-AA-1094 and Process ESD Philosophy Doc# 5906G-GL-RP-2007 00 for
details).

4.3.5 Export Gas Compression

The export gas compression system is controlled to maintain a constant suction
pressure, as described above, via compressor load sharing. Compressor discharge
pressure floats against gas export pipeline back-pressure. For details of the export gas
compressor system operating and control philosophy refer to supplier documentation.

Due to the complexity of the compressor system, it is vital to use dynamic simulation
during detailed design.

4.3.6 Temperature Control

Feed gas temperature to the Warm Separator (C-581) is controlled by cold gas bypass
around the First Gas/Gas Exchanger (E-551) via TV-5504B (in a manner that when TV-
5504A begins to close, TV-5504B begins to open) in the upstream of the Warm
Separator, to minimise the risk of wax formation in the chiller unit.

The Gas/Liquid Exchanger (E-591) gas outlet temperature is controlled by throttling the
gas feed to the exchanger.

During plant operation, the controlled temperature to the Warm Separator will be
optimised for the specific gas composition / operating conditions. A review of the four
base case simulations show that this controller set point will be of the order of 51oF and
42oF for the Rich Hot and Rich Cold cases and 56oF and 43oF for the Lean Hot and Lean
Cold cases.

The export gas hydrocarbon dew point is controlled by setting the propane chiller outlet
temperature. This temperature control loop is included within the scope of the propane
refrigeration package. Refer to the propane refrigeration package supplier
documentation for details.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 13 of 18

4.3.7 Parallel Heat Exchanger Operating Mode Control

Operation of the gas cooling train in the alternative parallel operating mode makes use of
existing temperature control and uses additional manual balancing valves in the parallel
piping arrangement.
The control of the Gas/Liquid Exchanger (E-591) is unchanged, except that the control
set point of the temperature control loop needs to be lowered to the desired value,
approximately 32oF. The gas outlet temperature is controlled by throttling the gas feed to
the exchanger.
The control of the First Gas/Gas Exchanger (E-551) and Second Gas/Gas Exchanger (E-
571) uses the existing temperature control loop on the First Gas/Gas Exchanger and
manual balancing valves. The control set point of the temperature control loop needs to
be lowered to the desired value, approximately 32oF and manual balancing valves on the
warm feed gas inlets to the First Gas/Gas and Second Gas/Gas Exchangers and on the
cold gas inlet to the Second Gas/Gas Exchanger, will be adjusted to balance the flows
and to achieve the desired outlet temperature (to the Warm Separator).

4.3.8 Test Separator

Each production well is diverted to the Test Separator via the Inlet Test manifold and
separation of streams and control will be as described in section 4.3.2 of this document.

Well Testing will be achieved through the use of flow computers which will measure,
totalise and record the flowrates of the separated streams for each well under testing.
The gas flowrate will be recorded at specified pressure and temperature while the
condensate flow rate will be recorded at specified temperature values. Water stream
exiting the vessel via the boot will also be measured, totalised and recorded for each
well.

4.3.9 Process Facilities Interface with Phase I existing Facilities

The Phase 2-Phase 1 interface are summarised below(please refer to the latest revision
of the Tie-in list Doc# 5906G-GL-P-LS-2079 00 for interface and Tie-in point details):
A cross-over line capable of diverting 60MMSCFD of Gas under flow control from Phase
2 to Phase 1 is located upstream of the Slug Catcher gas outlet flow control valve. The
flow controller is under manual reset and can be adjusted as necessary.

Condensate export pumps will pump stabilized and on-specification (max RVP =12psia)
condensate from Phase 2 to Phase 1 crude export line via the condensate metering skid.
These pumps will also send off-specification condensate to the flare Knock Out drum.
The route of the condensate will be controlled from an on/off spec switch which will divert
the flow through one of the level valves on the condensate lines.

Fuel gas for start-up of Phase 2 will be taken from the Phase 1 export gas pipeline. The
gas will be flowed to Phase 2 under pressure control triggered by a manual switch in the
HP Fuel Gas DCS logic.

Instrument and utility air will be cross exchanged between the Phases 1&2
Instrument/Plant Air Packages respectively.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 14 of 18

Fire Water will be pumped from Phase 1 5000bbls water storage tank by the diesel
engine driven pump rated for 1500GPM at 160psi differential to Phase 2. Fire Hydrant
points will be located strategically at different location in the Phase 2 plant.(Please refer
to the latest revision of the “Fire Water System Study”,Doc.# 5906G-GL-P-RP-2077 00)

Degassed water from Phase 2 will be pumped from the Water Degassing Drum to the
BS&W pit in phase 1. Level control signals from the drum will be utilized to control the
operation of the pumps.

Liquid Hydrocarbon Drains and off-specification Condensate will be pumped from the
Phase 2 Closed Drain Drum to Phase 1 Wash Tank or the Burn Pit. The pumps operation
will be modulated by a flow controller receiving signals from a level transmitter installed in
the drum.

Export Gas Compressors discharge will be routed to the Gas Metering Package through
a common header. The metered gas will be delivered to the Zuetina pipeline in Phase I
via a coated, lined and wrapped underground pipeline.

4.4 Condensate Processing

4.4.1 Reception Facilities

Vapour and liquids arriving at the gas plant downstream of the flowlines from the gas
production wells will disengage in the Slug Catcher. Vapour will flow into the gas
processing facilities and the hydrocarbon liquids will be routed under flow reset by level
control to condensate stabilisation. The water separated in the Slug Catcher will be
routed to the Water Degassing Drum under interface level control.

High pressure switches on the flow lines will close the ESV valves on the flow lines and there
is no provision for automatic blowdown of the Slug Catcher. If an emergency arises requiring
depressurising of the Slug Catcher, it can be done only as an operator controlled operation.
This will require the production manifold inlet valves (either the MOVs or the manual valves)
to be closed by the operator prior to blowdown.

In view of the high inventory of production fluids to be handled by the Slug Catcher,
additional safeguard have been provided by using 600# rated pipes and it is only under an
extreme emergency that a blowdown action should be initiated by the operator. Emergency
isolation / blowdown of the Slug Catcher is to be further developed during detailed design.

When a flowline is routed to the three-phase Test Separator, the feed stream is
separated to Gas, Condensate and water. The separated Gas is sent under pressure
control to the inlet line feeding the TEG Dehydration unit while the condensate is routed
under level control to the Stabiliser Feed Drum. The water is collected in a boot and
routed, under interface level control, to the Water Degassing Drum.

The Test Separator is fitted with an automatic depressuring valve which can be opened
via a level 4 ESD caused by high-high pressure in the vessel. Manual depressuring can
also be initiated by the operation by opening the blowdown valve on the PSV inlet bypass
line.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 15 of 18

4.4.2 Condensate Stabilisation

Condensate from the Slug Catcher is routed under flow reset by level control to the
Stabiliser Feed Drum. Secondary condensate streams from the Glycol Dehydration
Package, Warm Separator, Test Separator, Chiller Unit, Export Gas Compressor Drums,
Recycle Gas Compressor Drums and HP Fuel Gas KO Drum are routed, under level
control, to the Stabiliser Feed Drum.

On high liquid level in the Stabiliser Feed Drum the feed drum level controller will act to
throttle the Slug Catcher condensate flow control valve. This control action will seek to
maintain liquid level in the Stabiliser Feed Drum by backing up condensate in the Slug
Catcher.

Off gas from the Stabiliser Feed Drum is routed under pressure control to the suction of
the Recycle Gas Compressors. Condensate flows to the Stabiliser Column in two
streams: one is the reflux; the other is the main feed. The feed to the top tray acts as a
cold reflux for the Stabiliser Column. The Stabiliser feed drum liquid level controller
provides the set point to the column feed flow controller, routing condensate to tray 6 of
the Stabiliser via the Feed Bottoms exchanger. A ratio controller takes the flow signals
from the reflux and the feed flows to the Stabiliser column. This (ratio) controller resets
the set point of the reflux flow controller. It allows the flow to the column to be split 25:75
(reflux : feed). At low turndown rates, i.e. rates below the top tray feed flow control set
point; a lower reflux set point clamp will prevent flow from dropping below a minimum
value. The hot feed to the column is temperature controlled by by-passing bottoms liquids
around the Feed Bottoms Exchanger. This is achieved by the use of a three-way valve on
the condensate rundown line, which can divert flow from the shellside of the heat
exchanger E-651.

At turndown or upset conditions, the condensate temperature to the Condensate

Rundown Cooler will increase. Even with the total normal condensate flow being routed
to the Rundown Cooler at the Stabiliser Reboiler outlet temperature of 338oF, the design
margin on the Rundown Cooler is such that the condensate can still be cooled to
temperatures below the system design temperature.

Water is collected in the Feed Drum boot and is routed, under interface level control, to
the Water Degassing Drum.

Stabiliser Column operating pressure is maintained constant by overhead pressure

control, routing the off gas (combining it with the gas from the Stabiliser Feed Drum) to
the suction of the Recycle Gas Compressors.

The Stabiliser Reboiler provides the reboil duty for the Stabiliser Column. A flow
controller downstream of the Stabiliser Reboiler Pump sets the flow to the reboiler. The
Stabiliser Reboiler Pumps are configured as 2x100% duty pumps, on auto start on low
flow. The heater firing rate is controlled against the temperature of liquid on tray 19 of the
column.

Stabilised condensate from the Stabiliser Column is routed through the Feed Bottoms
Exchanger and Rundown Cooler and pumped via the condensate metering package
directly to the existing Faregh Phase 1 crude export line by the Condensate Export
Pumps. The export rate is controlled by the Stabiliser Column bottom level control, acting
on a control valve on the Condensate Export Pump discharge. The Condensate Export
Pumps are configured as 3x62.5% duty pumps, on auto start on low flow.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 16 of 18

An online RVP analyser located downstream of the condensate cooler is provided for
detection/alarm of off-specification condensate. Routine condensate sampling will also be
carried out. For production of on-specification condensate, the stabilised condensate will
be routed to the export pipeline via the metering skid via LV6514B. On detection of off-
specification condensate, the condensate flow via the condensate metering package to
export will be switched using a software switch in the CCS. The off-spec condensate will
be routed to the LP Flare KO Drum, via the HP Flare KO Drum by opening the ‘A’ valve
and closing the ‘B’ valve. Off-specification condensate liquids are first flashed in the HP
Flare KO Drum to the HP flare system operating pressure, then routed to the LP Flare
KO Drum and flashed to LP flare system operating pressure and pumped to the Phase 1
Wash Tank.

The design of the phase 2 plant assumes that any off-spec condensate produced will be
routed to Phase 1 wash tank and there is no provision within the plant to measure the
RVP of the off-spec condensate routed through the flare KO drums. Also, there is no
alternative provision to store off-spec condensate in Phase 2 and any limitation as to the
capability of the Phase 1 wash tank to process the off-spec condensate from Phase 2 is
not within the scope of this design.

Return to normal operation will be by manual reset of the ESD valves tripped by the
action caused by off-spec detection. This manual reset operation can be reviewed further
in the course of project execution.

If there is a rising level in the stabiliser column base, the base level controller output will
first fully open the ‘B’ valve. If the base level continues to rise the level controller will start
to open the off-specification ‘A’ valve using a split range configuration. As the level of
fluid at the base of the stabiliser returns to normal, the off-specification ‘A’ valve will
return to close while the on specification ‘B’ valve returns to normal operating range.
Excess condensate coming into the plant can be held up in an additional volume
allowance in the Slug Catcher (two hours at design rate is provided).

Any water draw off required from the Stabiliser Column will be manually controlled by
periodic visual inspection of the stabiliser column water pot sight glasses.

4.4.3 Recycle Gas Compression

The recycle gas compression consists of three motor driven reciprocating machines (2
operating with 1 spare) to compress off gas from the condensate stabilisation unit and
return it to the gas processing train upstream of the gas dehydration equipment.

The discharge pressure of the Recycle Gas Compressors will float on the inlet pressure
to the gas dewpointing facilities. Careful control of the compressor aftercooler outlet
temperature is required to minimise liquid knock out at low ambient temperature.

On reduced stabiliser off gas throughputs, a pressure transmitter on the recycle gas
compressor suction will provide an input signal to the Recycle Gas Compressor load
sharing control system. The control system will first act on a control valve in the
compressor recycle line and then on the compressor capacity control system (unloading
valves, refer to supplier documentation) to maintain suction pressure.

Suction pressure will be maintained at gas throughputs in excess of recycle gas

compressor capacity by a spill off valve to HP Flare.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 17 of 18

4.4.4 Propane Refrigeration Package

Refer to vendor documentation for the operating and control philosophy for the Propane
Refrigeration Package. The proposal from the vendor will be subject to review to ensure
that it conforms to the overall Process Operating & Control Philosophy of the Faregh
Phase 2 gas Plant.

4.5 Utility Systems

4.5.1 General

The utility systems, which are not supplied from the existing Faregh Phase I Gas Plant
will be supplied as vendor designed packages which may have their own control and
safety systems to provide safe and efficient operation with little operator attention. If
stand alone control systems are used certain alarm and shutdown signals will be relayed
to/from the CCS.

Shutdown signals shall be hard wired, monitoring signals may either be via serial
communication interfaces or hard wired.

4.5.2 Closed Drains System

Hydrocarbons drained from the process equipment on an intermittent basis may be

volatile presenting a flammability risk. Therefore a closed system will be provided. Drains
from equipment are hard-piped into the closed drain header.

The closed drains headers will gravity drain into the Closed Drain Drum, which vents
directly to the LP flare system. In order to accommodate gravity draining, the Closed
Drain Drum will be buried.

The closed drains liquids are pumped by the Closed Drains Pump (G-701 A/B) (2x100%
submerged suction pumps) to the Phase 1 Wash Tank, which, will effect basic
condensate/water separation. The closed drains pumps shall be operated on start/stop
level control. The pump discharge routing can also be switched to the Burn Pit.

4.5.3 Process Water Degassing System

There is a continuous water flow from the Slug Catcher, which contains very small
amounts of hydrocarbons and dissolved hydrocarbon gases. This water is degassed in a
degassing drum, which vents to the LP flare. Water is routed from the drum to the
existing Phase 1 BS&W pit under on/off level control. Water degassing Drum pump will
start on LSH and will stop on LSL and outlet level control valve will modulate between
LSH and LSL.

HP and LP Flare KO Drums

Details of the design of the HP and LP Flare KO Drums, relief and flare rates and flare
operation are covered in the Process Flare, Vent and Relief Philosophy, document
5906G-GL-P-RP-2008-00 and Flare Network Report, document 5906G-GL-P-RP-2076
00..

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008
 WAHA OIL COMPANY
FAREGH FIELD DEVELOPMENT PHASE 2
TITLE PROCESS OPERATING AND CONTROL REV DATE PAGE NO.
PHILOSOPHY
DOCUMENT 5906G-GL-P-RP-2006-00 E 03-Jan-08 18 of 18

The HP Flare KO Drum liquid is pumped from the vessel, by the HP Flare KO Drum
Pump, (3x60% units) to the LP Flare KO Drum. These pumps will start sequentially by
raising the level in HP Flare KO Drum. During high level in LP KO Drum, the pump
discharge routing can also be switched to the Burn Pit.

The LP Flare KO Drum liquid is pumped from the vessel, under on/off level control, by the
LP Flare KO Drum Pump (3x60% units) to the Phase 1 Wash Tank. The pump discharge
routing can also be switched to the Burn Pit.

5.0 WAHA CENTRAL INTERFACE

All interfaces between Waha Central and the Faregh Phase 2 facilities will be shown on
the P&IDs (selected control and monitoring). Actual details of what information will be
available will be developed during detailed design.

5906G_GL_P_RP_2006 00 Rev E IFD PROCESS OPERATING & CONTROL PHILOSOPHY, January 3rd, 2008