Subcontract Title: General Construction Work (Gas Compressor Station )
Client : KBR
Subcontractor : DALHAM Co.- IRAQ
Project Duration: June 2006- Feb 2007
Preview:.jpg)
Project is an existing gas compressor station, operated by the South Oil Company (SOC) in South Rumailah, Iraq .It is one of four compressor station in South Rumailah and it is the highest gas producer. It was originally constructed in 1976 and 1977 by Nippon Kokan and Bechtel; it was damaged during the hostilities from 1991 Gulf War through 2003. In addition to the war damage, the facility has suffered from a lack of spare parts, from aging equipment, obsolete technology and from some looting which occurred during the general confusion of the war. Within the compression station there is a gas dehydration unit which is completely damaged, the old damaged equipment have been removed with their concrete foundations and new equipment with new foundations have been installed and connected to the remaining existing facilities.
Project Activities:
1. Contactor / Absorber tower.
The dimensions of the tower are 3.12 m Diameter and 12.85 m High with weight of 40.8 ton. The installation of the tower has been done by using two cranes 300 ton and 50 ton capacity. Installation plan has been created by Snafee staff and approved by KBR engineering department before the installation.
The installation includes leveling grouting and final bolts tightening.
2. Inlet Decanter Separator tower.
The dimensions of the tower are 2.97 m Diameter and 6.5 m High with weight of 20.9 ton. The same cranes as above used after the approval of the installation plan by KBR.
The installation includes leveling grouting and final bolts tightening.
3. Dehydration package Unit includes Re-boiler, Flash Tank & Accumulator.
This unit arrived as parts in big boxes, the assembly and installation has been done on site using same cranes above, the total weight of the equipment is 67.28 ton. Installation plan from four stages has been created by Snafee staff and approved by KBR engineering department before the installation.
The installation includes leveling grouting and final bolts tightening.
4. Inlet Gas cooler / Glycol cooler
The dimensions of this cooler are 13.716 m L, 5.791m W, 3.658 m H, with weight of 18.8 ton, the problem with installation of this cooler was its location which does not give close access of the crane to this location, creating installation plane using the 300 ton crane the cooler was successfully installed.
The installation includes leveling grouting and final bolts tightening.
5. Air Compressor skid.
This skid include two reciprocating compressors with two coolers, two dryers, air receiver, interconnection piping and control panel, the dimensions of the skid are 6 m L, 3 m W, 2.6 m H, with total weight of 21 ton.
The installation includes leveling grouting and final bolts tightening.
6. Low pressure condensate pump.
These are two pumps on two base plates with dimensions 2.25 m L, 1 m W, 0.68 m H each.
7. Fabricating and installing of new Glycol Storage tank.
New Glycol supply tank has been designed, fabricated and installed by Snafee project team the tank capacity is 1.5 m3 with operating pressure of 1.5 bar.
8. Fire Water Jockey pump.
This is a small centrifugal pump installed to strengthening the fire water system in the station.
1. Underground piping.
The installation of the underground piping include excavation of trenches with suitable depth, fabrication, welding, X-Ray test, hydro test, insulation, insulation test and backfilling with compacting of the soil up to 95% min.
The underground system includes the following pipe sizes with lengths and fittings, 8" 120m, 4" 120m, 3" 150m, 2" 100m and 1" 160m. 2. Aboveground piping.
The installation of the aboveground piping includes fabrication of piping to connect between the installed equipment, welding, X-Ray test, hydro test and painting.
The aboveground system includes the following pipe sizes with lengths and fittings, 16" 100m, 12" 50m, 6" 55m, 4" 25m, 3" 60m, 2" 45m and 1.5" 70m.
The project include excavation of trenches with suitable depth, laying two layers of cable, power cables and control cables with total trench length of 300m, backfilling with sand, soil, concrete tiles and warning tape.
During the project some old equipment has been replaced such as:
1. Check valves.
2. Gate valves.
3. Ball valves.
4. MOV Ball valves.
5. Pressure safety relief valves.
6. Different type of instrument.
The project includes installation of different types of instrumentations, terminations, loop check and test run. Plus installation of PLC unit and matching it with the existing control system.