Arabian American Center Details Training & Development
Program Title:
Transportation and Distribution Foundations
23.08.2020 - 27.08.2020
$ 3900


Course Objective:

                • Learn the fundamentals of pipeline network operations.

                • Learn the location of all collection and distribution networks within KOC.

Target Audience

         All staff working in the field

Training Methodology

   A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. Questions, comments and personal experience from every participant will have a chance to be heard and discussed. Tests of multiple-choice types will be made available on a daily basis to examine the effectiveness of delivering the course.

   Case studies are encouraged to be brought by the participant. These case studies will be discussed thoroughly and will be shared by all participants.

Day 1 1-Piping Network fundamental & operation:

          Network consists of:

                • Underground pipelines with varying sizes (3"-52"), tot – length 3200 KM

                • DNV risk account contract

                • Dynamic simulation

                • Pipe line integrity

                • Gas pipeline debottlenecking industrial applications

         Oil Operation facilities

         Crude Oil Production:

                 o Old CRU: Limited to old design capacity to minimize Gas Flaring.

                 o New CRU: Enhanced Production capacity up to 160,000 BOPD with a very low rate Gas Flaring.

        Facts &Challenges

        Compression Availability:

                 o Old Design: if the CRU is down…. 100% flaring of tanks vapour (loss of revenue).

                 o New Design: If the new CRU is down…. Old CRU is available and can be On‐stream within

                    an hour… minimum Gas Flaring (minimum loss of revenue). – Enhanced Maintenance Program.

                 o Challenges: – Operate efficiently in a Safe Manner. – Achieving Target Crude Production

                   with Minimum Gas Flaring. (2) Effective Correct

       2-Network layout and philosophy

                • Oil and natural gas(Growth of market, Construction and operation), Ammonia, Coal and

                     ore, Hydrogen, Water, Marine pipelines,Functions, Development and planning, Operation,

                    Technology(Components, Leak detection systems), Implementation, Maintenance, Regulation,

                    Pipelines and geopolitics, Hazard identification, Exposure


             Five Lessons learn

                              (1) Operate Efficiently

                              (2) Effective Corrective Maintenance

                              (3) Reliable PM

                              (4) Analytical Study

                              (5) Continuous Operator Training


               o For Multiple Gathering Centers of different Production Capacity, select equipment

                  design capacity to suit rather than over/under design.

               o Select new equipment based on: – Energy Efficiency (e.g. Variable Speed Driver), –

                   High Reliability (e.g. >97%). – High Availability (e.g. >95%).

               o Continue raising budgets for future projects.

               o Monitor installing and commissioning the existing projects and the ongoing ones

                 (down the tube).

 Day-2 3-Types of networks in KOC ( Rich Gas Network)

           LP rich gas network

               o From NKGCs 42"LPRich gas line to BS -131

               o From Ek-GCS 36" LP rich Gas Line to BS-140

               o From SEk – GCS 42" LP Rich Gas to Proposed BS – 180

               o Sk-GCS 42" LP Rich Gas Line to Bs – 160

               o From 18" LP Gas line from(Wafra) to Bs- 170& GC – 17

               o From 3x36" LP Rich gas line to BS -131

          HP rich gas network

               o From EK-Gcs 36" HP Rich Gas line to Bs – 140

               o From Bs -140 to Gcmb 20" & 30" HP Rich Gas line

               o From SEk-Gcs 30" HP Rich Gas ( 2 lines) to Bs – 160

               o From Sk-Gcs 36" HP Rich Gas Line to BS- 150

               o From Bs- 150 to GCMB

               o From New Gc-160 to AGRP- 24" HP Gas Line

               o From NK Gcs 36"HP rich gas line to Bs - 131

                                  • Condensate

                                  • HP lean gas/fuel

                                  • LP lean Gas/fuel

      4-HFO (Heavy fuel Oil)

               o Classes

               o Bunker fuel

               o Uses

               o Maritime

               o Standards and classification

               o Transportation

               o Environmental issues

               o Meanings of "bunkering"

                                  • Gas Oil Network,

                                  • Crude oil supplied to MEW

Day-3 5-Types of valves

         MOV, GOV, AOV & Types of drip barrels and troubleshooting

               o Theory of Operation of Valves

                                  • Rising-Stem Valves – Gate & Globe Valves

                                  • Quarter-Turn Valves – Ball & Butterfly Valves

                                  • Limit torque Actuators – SMB, SB, SBD, & HBC

                                  • Rotork Actuators

               o Theory of Valves Design Basis Operation

                                  • Valves Functional Margin

                                  • Design Basis Valve Stem Thrust

               o Theory of valves Design Basis Operation

                                  • Design Basis Valve Stem Torque

                                  • Motor Actuator Output Capabilities

               o Valves Laboratory – Limit torque actuator disassembly,

               o Assembly, and switch setting

               o Regulatory Requirements

               o Valves Laboratory – Diagnostic Testing and Troubleshooting

                                 • Theory of Valves Controls

               o Torque Controlled Valves

               o Limit Controlled Valves

                                 • Periodic Verification

               o ASME Code

               o Diagnostic Testing and hydrostatic tests API 598

                                  • Lessons Learned

        6-Basics of network operations

                • Isolation,

                • Purge,

                • De-pressurize and pressurize

        7-Manual network operation and control

        8-Guidelines for the definition of gas gathering lines

               o Gathering pipeline terminology

               o API 80

        9-Sludge catcher operations

               o Slugs Terminology

               o Purpose of the slug catcher

               o Slug catcher design

               o Benefits of the Catcher

Day- 4 10-Pre / Post-startup procedures

               o pre Start-up procedure

                                 a) Verify the Pr-Commissioning, Commissioning pre start up activities

                                 b) Verify component installation

               o Start-Up Procedures

                                 a) start the main equipment and machines

                                 b) Verify the plant steady operation

                                 c) Monitored and adjust the rotating equipment speed to reach to the vendor


               o Post Start-Up Procedures

                                a) reach to the plant operating in steady state with the production monitoring

                                b) Safety checkout

         11-Purge in / purge out procedures

               o Ten hazards involved in purging natural gas piping

        12-Gas utilization options and techniques

                • Major parameters that play a role in the screening of gas utilization options include:

                                 Gas-field size

                                 product market size

                                 World-scale plant size

                                 Maturity of technology

                                 Capital cost

                                 Product prices


                • Basic understanding of pipelines and operational needs

                       o Project implementation Services :

                                 Feasibility study, Project planning & scheduler, Detailed engineering, Mat.

                                     Procurement, site construction, commissioning and start up etc.

                       o Specialists Services

                                 Heat and mass Balance, Environmental engineering, special Material ,etc

                • Introduction to oil and gas fluid transport properties

Day 5 14-Flaring

                • Definition and need to flare

           Flares–What are they?

                • Overprotection devices

                • Different types and applications of flares

                        o Flare Types

                                 Single point

                                 Multi-point (finger types)

                                 Enclosed

                • Flare operation, maintenance and monitoring

                         o Why Flaring

                         o Flare System Major Components

                         o Series of collection headers from sources

                         o Knockout drum

                         o Stack

                                  Flare Tip

                                  Liquid seal „

                                  Purge reduction device (stack seal)

                         o Integrated pilot system „

                         o Monitoring and operation instrumentation

                         o Flare hydrocarbon recovery systems

                         o Flare System Purge Requirements F

                • Flare safety

                         o Process Safety Management (PSM)

                         o API 537 paragraph 4.1

                • Flaring control

                         o Typical Flows to Flare Systems

                                  Emergency

                                  Episodic

                                  Continuous – 99+% of Typical Operation

                        o Hydraulic Design & Issues

                        o Flare System Operational Controls

                                  Steam or air flow to flare tip „

                • Cooling (minimum flow) „

                        o Protection for metal Protection for metal „

                        o Eliminate internal burning (center steam)

                • Smoke control „

                        o Upper steam „

                        o Steam Air tube steam (larger tip size only) „

                        o Center steam Center steam „

                 • Keep steam hot (minimize condensate) „„

                                 Knock -out drum liquid flow „

                                 Assist gas flow „

                                 Collection header purge

                                 Oxygen level in flare header „

                                 Pilot ignition

                       o Flare System Monitoring Instrumentation

                                 Video camera Video camera

                                 „ Pilot gas flow and temperature

                                 „ Relief gas flow, pressure, temperature and composition

                                 „ Knockout drum level

                                 „ Water seal level, pressure, and temperature

                                 „ Steam flow to flare

                                 „ Collection header purge gas flow

                                 „ Flare gas recovery

                       o Control and monitoring equipment may not be available for maintenance with

                            flare system in service

                       o „ Each flare system monitoring requirement is unique and can be different

                • Flare Maintenance

                       o Most major maintenance has to occur during a turnaround

                       o Consideration for T/A inspection, PM, repair or replacement

                                Pre T/A survey– e.g... drone technology

                                Pilots

                                Thermocouples

                                Clean/check fuel and FFG piping for leaks and pluggage

                                Critical instrumentation

                                Stack riser

                                Guy wire connections at stack

                                Water seal

30 Sobbhy Fahmey St. - Ard El-Golf - Heliopolis - Cairo - Egypt
Tel: +201001029959/+201066687900/+202 24199019 – Fax: +202 24170419 E-mail:
ISO 9001:2008 Certificate No. 01 100 105040 - TUV Rheinland - Germany – WWW.TUV.COM