ORYX GTL Doc. No.

QGTL1-PMC-RP-XXXXX Page

TRAGS Doc. No. TRG-CIVIL-SSR-ORYX-024-17-0001 2/9

QATAR KENTZ Doc. No. MQAE010-1000-40ER-0001 Rev A

ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

TABLE OF CONTENTS

1.0 REVISION HISTORY ........................................................................................................ 3

2.0 INTRODUCTION............................................................................................................. 4
3.0 SCOPE ........................................................................................................................... 4
3.1. PROJECT BACKGROUND ................................................................................................. 4
3.2. OBJECTIVE ..................................................................................................................... 4
3.3. PROPOSED FACILITY/ INSTALLATION ................................................................................ 4
4.0 SITE VISIT DETAILS ........................................................................................................ 5
5.0 PIPING ........................................................................................................................... 6
5.1. OBJECTIVE- PIPING ......................................................................................................... 6
5.2. OBSERVATION- PIPING .................................................................................................... 6
5.3. CONCLUSION-PIPING....................................................................................................... 7
6.0 INSTRUMENTATION ...................................................................................................... 7
6.1. OBJECTIVE- INSTRUMENTATION ....................................................................................... 7
6.2. OBSERVATION / VERIFICATION - INSTRUMENTATION .......................................................... 7
6.3. CONCLUSION- INSTRUMENTATION .................................................................................... 8
7.0 ANNEXURES .................................................................................................................. 9
7.1. ANNEXURE-1 .................................................................................................................. 9
7.2. ANNEXURE-2 .................................................................................................................. 9

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TRAGS Doc. No. TRG-CIVIL-SSR-ORYX-024-17-0001 3/9

QATAR KENTZ Doc. No. MQAE010-1000-40ER-0001 Rev A

ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

1.0 Revision History

Revision Date Section / Pages Revised Reason for Revision

A 17/09/2018 First Issue for the Comments

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QATAR KENTZ Doc. No. MQAE010-1000-40ER-0001 Rev A

ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

2.0 Introduction
This document provides detailed report of the site survey carried out to perform Detailed Engineering Design
of Flare Minimization Plan (Part-1) - Tail Gas Firing along with Natural Gas in Unit-72 Boilers for ORYX GTL.
This report includes objectives, observation and conclusion made during the site survey by each discipline
participated.

3.0 Scope
TRAGS and SNC Lavalin shall carry out the site surveys to start the Detailed Engineering Design (DED) of
Flare Minimization Plan (Part-1) - Tail Gas Firing along with Natural Gas in Unit-72 Boilers to meet the project
objective.
The scope comprising this project for each boiler is to connect the TG line downstream of existing NG flow
control valve.
The Front End Engineering Design (FEED) package for the Project recieved from ORYX GTL is the basis of
Engineering in EPIC phase of the project.
The detailed site survey report for Piping, Civil & Structural and Instrumentation disciplines herein provided in
the sections 5, 6 and 7 of this document.

3.1. Project Background

The purpose of this project is to utilize the excess Tail Gas into Unit 72 boilers as much as possible rather
than burning it in flare. The main benefit from the project would be the reduced GHG (Greenhouse Gases)
emissions and improved energy and carbon efficiency of the facility.
This project has two aspects:
I. Changing NG firing to TG/NG mixed firing
II. Preparing TG/NG mixture
For changing natural gas firing to mix fuel (TG/NG) firing, a mixing facility is required to provide stable flow to
all three boilers.
No shutdown required for the integration of mixing facility with existing system. All necessary tie-ins are
already executed in previous shutdown.
Based on the above scope the Tie-Ins and individual mixing arrangements shall be designed based on the
FEED document.

3.2. Objective
The objective of the site survey is to validate the FEED engineering documents and identifying the necessery
details to carry out the Detail Engineering as per the scope.

3.3. Proposed Facility/ Installation

The proposed facility shall be designed such that the excess TG from plant fuel gas header will be mixed
with NG supply to boilers.
Individual Boiler TG/NG Mixing piping arrangement with necessary controls that will allow to consume excess
tail gas available as mentioned in the project scope and background.

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QATAR KENTZ Doc. No. MQAE010-1000-40ER-0001 Rev A

ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

4.0 Site Visit Details

The First site survey visit was conducted by the TRAGS/ SNC Lavalin representatives on 07/08/2018.
Location: Unit – 72, ORYX GTL Ltd, Ras Laffan Industrial City – State of Qatar.
Following are the attendees during site visit:

ORYX GTL LIMITED TRAGS / SNC Lavalin

- Mr. Yashwant Yadav – Sr. I&C Engineer
- Mr. Sundar Rajan SK - Engineer
- Mr. Sulfikar Ibrahim – Instrumentation Engineer

The Second site survey visit was conducted by the TRAGS/ SNC Lavalin representatives on 02/09/2018. and
photos have been taken during site survey.
Following are the attendees during site visit:

ORYX GTL LIMITED TRAGS / SNC Lavalin

- Mr. Bibin Viswambharan – Sr. Piping Engineer
- Mr. Sijo Sivan –Piping Engineer
Mr. Sulfikar Ibrahim - Instrumentation Engineer

The discipline wise objectives, observation and conclusion made during the site survey are herein detailed in
the section 5 and 6.

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ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

5.0 Piping
The site surveys were conducted to verify the location of proposed Tie –Ins and associated pipe routing, Tie–
in point’s location, support feasibility, valve operation/accessibility and maintenance space in line with the
scope of work. Details are as follows:

5.1. Objective- Piping

5.1.1. The objective of the site survey is to carry out the checking and verification of Tie- in’s from existing
Tail Gas header and continue further for distribution to three individual boilers 172-XP-001- A/B/C
and associated piping modifications, support feasibility, operation/accessibility, and maintenance
space for the proposed piping systems. Tie-in wise details are as follows:
a) To check the feasibility of Tail Gas tie-in (TP-01) at line no. 18"-FG-A1AP-72012-01-NI and routing
main header on pipe rack to the proposed three individual branch lines for each boilers 172-XP-
001- A/B/C.
b) To check the feasibility of routing of new Tail Gas line and Tie in to existing Natural gas control
valve skid as per FEED proposed location (TP-06 &07, TP-12 &13, and TP-18 & 19) at Natural
gas lines 10”-NG-A1AP-72009-V46-NI, 10”-NG-A1AP-72009-V110-NI & 10”-NG-A1AP-72009-
V174-NI respectively for boilers 172-XP-001- A/B/C.
c) To check the feasibility of routing the proposed new by-pass line for the existing natural gas
control station skids (Natural gas lines 8”-NG-A1AP-72009-V45-NI, 8”-NG-A1AP-72009-V109-NI
& 8”-NG-A1AP-72009-V173-NI) and tie-ins (TP-04&05, TP-10&11, TP-16&17) respectively for
boilers 172-XP-001- A/B/C.
d) To check the feasibility of routing the proposed new Flare Vent lines from Tail gas control
stations and tie-in (TP-02&03, TP-08&09, TP-14&15) to Existing Vent gas lines 2"-VF-A2AP-
72009-72-NI, 2"-VF-A2AP-72009-73-NI & 2"-VF-A2AP-72009-69-NI respectively for boilers 172-
XP-001- A/B/C.

5.2. Observation- Piping

5.2.1. Identified and verified the proposed new Tail Gas pipe routing, Tie-Ins, associated piping
modifications, support feasibility, operation/accessibility, and maintenance space requirements (Refer
Annexure -1). Tie-in wise details are as follows:
a) Identified and verified the proposed Tail Gas tie-in location (TP-01) at line no. 18"-FG-A1AP-
72012-01-NI and routing on pipe rack (East-West ) to each steam generator Boilers 172-XP-001-
A/B/C. (Refer Annexure -1 Figure-1)
b) Identified and verified routing for FEED proposed location of new Tail Gas line control valve
arrangements and tie-ins (TP-06&07, TP-12 &13, and TP-18&19) at Natural gas lines 10”-NG-
A1AP-72009-V46-NI, 10”-NG-A1AP-72009-V110-NI & 10”-NG-A1AP-72009-V174-NI respectively
for steam generator Boilers 172-XP-001- A/B/C. (Refer Annexure -1 Figure-2)
It is observed that, option to install the new Tail Gas control valve station at east side of boilers will
be complex in design for providing sufficient operation and maintenance access. Additionally this
design will cause to obstruct the existing mono rail movements towards east side for burner
maintenance. Hence the Tail Gas control valve assembly is proposed to relocate to north side of
the Boiler.

This option satisfies the installation, operation and maintenance requirements for valve station and
surroundings. (Refer Annexure -1 Figure-5).

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ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

c) Identified and verified the routing of proposed new by-pass line for existing Natural Gas Control
Valve assembly and tie-in’s (TP-04&05, TP-10&11, TP-16&17) to existing lines 8”-NG-A1AP-
72009-V45-NI, 8”-NG-A1AP-72009-V109-NI & 8”-NG-A1AP-72009-V173-NI respectively for
Boilers 172-XP-001- A/B/C. (Refer Annexure -1 Figure-3)
d) Identified and verified the proposed new Flare Vent lines from Tail Gas Control Valve station and
tie-in (TP-02&03, TP-08&09, TP-14&15) to existing vent gas line no. 2"-VF-A2AP-72009-28-NI, 2"-
VF-A2AP-72009-29-NI & 2"-VF-A2AP-72009-30-NI respectively for the Boilers 172-XP-001-
A/B/C. (Refer Annexure -1 Figure-4)

5.3. Conclusion-Piping
5.3.1. New Tail Gas line Tie –In and routing on Pipe rack is feasible with proper support arrangements till
each steam generator Boilers 172-XP-001- A/B/C.
5.3.2. Tail Gas distribution from Tail Gas Header to three individual boilers 172-XP-001- A/B/C, tie-in points
and associated piping routing and modifications are feasible considering the installation, maintenance
and operation requirements.
5.3.3. Tail Gas Control Valve assembly location is proposed to relocate to North side instead of east side
(FEED proposed) of boiler considering the installation, maintenance and operation requirements.
Refer 5.2.1(b)

6.0 Instrumentation

6.1. Objective- Instrumentation

6.1.1. The overall objective of Instrumentation site survey was to identify the locations for the additional
instruments, existing junction boxes, relocating existing on-off valves and addition of new positioners
on existing actuator of dampers. It also includes verification of spare availability in the junction boxes
for connecting secondary cable of new instruments.
Following were the defined objectives of the survey,
a) Identification of location for following new instruments to be installed as pert part of project
scope.
• 172-PT-0032, 172-TT-0031, 172-FT-0631/ 0731/ 0831, 172-FV-0631/ 0730/ 0831 & 172-FV-
0630B/ 0730B/ 0830B.
b) Identification of location for dampers (172-HV-0657/ 0667/ 0757/ 0767/ 0857/ 0867) to install
new positioners (DVC6200) on damper actuator.
c) Identification of new locations for relocation of existing on-off valves (172-XV-0630/ 0730/
0830).
d) Identification of existing Junction boxes to be used to wire the new instruments.
e) Identification of spare terminals in terminal block inside junction boxes and spare pairs of main
cable which is already connected to RIB1 marshalling panels.
f) Study of existing site condition for routing of new secondary cables to the existing Junction
Boxes and existing Air Distribution Manifolds required for control valves/ positioner’s of damper.
6.2. Observation / Verification - Instrumentation
6.2.1. The location of new instruments to be installed as per scope of work has been identified.

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QATAR KENTZ Doc. No. MQAE010-1000-40ER-0001 Rev A

ORYX GTL LIMITED

RAS LAFFAN INDUSTRIAL CITY - QATAR

6.2.2. New location of on-off valve to be relocated has been identified.

6.2.3. The secondary cable routes were identified and approximate cable length required has been
assessed.
6.2.4. The location of Air Distribution Manifolds (ADM) to supply Instrument Air to new valves has been
identified.
6.2.5. The spare manifolds available on existing ADM shall be utilized. The ADM tags are not found at site.
6.2.6. Location of existing Junction boxes has been identified.
6.2.7. Existing Junction boxes opened and spare terminals in terminal strip and spare pairs in main cable
have been identified.
6.2.8. It was concluded that new secondary cables from the existing junction box to the new instruments
shall be routed through existing trays as far as possible. Short length of 50mm tray may be laid for
the cables up to existing tray with proper support.
6.2.9. The location of dampers has been identified but tags numbers for damper are observed as 172-XV-
0657/ 0667/ 0757/ 0767/ 0857/ 0867.

6.3. Conclusion- Instrumentation

6.3.1. Location of the new instruments & modification / relocation scope for instruments were identified.
6.3.2. Location of existing Junction boxes for connecting new instruments’ secondary cables were identified
and new instruments shall be wired to respective junction boxes as follows; for more details refer
Annexure – 2, figures 1 to 4.
New Instrument Tag No. Existing Junction Box No.
172-HV-0657 & 0667, 172-PT-0032 & 172-TT-0031 172-JBL-0600
172-FT-0631, 172-FV-0631 & 172-FV-0630B 172-JBL-0602
172-FZXSC-0631 & 172-FZXSC-0630B 172-JBA-0606
172-HV-0757 & 172-HV-0767 172-JBL-0700
172-FT-0731, 172-FV-0731 & 172-FV-0730B 172-JBL-0702
172-FZXSC-0731 & 172-FZXSC-0730B 172-JBA-0706
172-HV-0857 & 172-HV-0867 172-JBL-0800
172-FT-0831, 172-FV-0831 & 172-FV-0830B 172-JBL-0802
172-FZXSC-0831 & 172-FZXSC-0830B 172-JBA-0806
All required terminals on terminal strip in above mentioned junction boxes to connect new secondary
cables have been identified.
Subsequent to relocation of on-off vales (172-XV-0630/ 0730/ 0830), the existing terminals of
following junction boxes shall only be used.
Existing Instrument Tag No. Existing Junction Box No.
172-ZXSC-0630 & 172-ZXSO-0630 172-JBA-0606
172-XV-0630 172-JBS-0609
172-ZXSC-0730 & 172-ZXSO-0730 172-JBA-0706
172-XV-0730 172-JBS-0709
172-ZXSC-0830 & 172-ZXSO-0830 172-JBA-0806
172-XV-0830 172-JBS-0809

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New secondary cables for relocated on-off valves shall be used incase existing secondary cables are
not sufficient and existing secondary cables shall be demolished.
6.3.3. New secondary cable routing feasibility was reviewed and approximate secondary cable lengths were
assessed as 30 mtrs. (approx.) for each tag.
6.3.4. The spare manifolds on existing ADM and approximate air tubing length has been identified.

7.0 Annexures
7.1. Annexure-1
Piping
[5 Pages excluding cover sheet]

7.2. Annexure-2

Instrumentation & Control

[4 Pages excluding cover sheet]

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7.1 ANNEXURE-1

PIPING
[5 Pages excluding cover sheet]

TC-CN-024-17-EN (MOC-1405)
 Proposed Location of Tail Gas Tie-in (TP-01)

Proposed Tail Gas Line Routing on

Pipe rack (E to W) from TP-01 to
steam generator Boiler 172-XP-
001- A/B/C .

Existing line no.

18"-FG-A1AP-72012-01-NI

TP
01

MQAE010-1000-40ER-0001_ANNEXURE-1 - PIP Figure-1

 Proposed location of new Tail Gas tie-in at Natural gas lines Typical for
steam generator Boiler 172-XP-001- A/B/C

TP TP TP Proposed Location of Tail

Gas line Tie-in at Existing
19 13 07 Natural Gas line

Existing Natural Gas line

TP TP TP
06 12 18

MQAE010-1000-40ER-0001_ANNEXURE-1 - PIP Figure-2

 Proposed location of new By-pass Line at Natural gas line Typical for
steam generator Boiler 172-XP-001- A/B/C

Proposed Tie-in Location

of Bypass Line at Existing
Natural Gas line

TP TP TP
04 10 16

TP TP TP
05 11 17

Existing Natural Gas line

MQAE010-1000-40ER-0001_ANNEXURE-1 - PIP Figure-3

Proposed location of New Vent Gas Line tie-in at Existing Vent Gas Line Typical for
steam generator Boiler 172-XP-001- A/B/C

Existing Vent Gas line

Proposed Location of Vent

Gas Line tie-in
TP TP TP
03 09 15

TP TP TP
02 08 14

MQAE010-1000-40ER-0001_ANNEXURE-1 - PIP Figure-4

New Tail Gas control valve assembly is proposed to relocate to north side of the Boiler.
Typical for steam generator Boiler 172-XP-001- A/B/C

Existing mono rails

movements towards east
side for the burner New Tail Gas control valve assembly is
maintenance proposed to relocate to north side of the
Boilers.

MQAE010-1000-40ER-0001_ANNEXURE-1 - PIP Figure-5

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ORYX GTL LIMITED

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7.2 ANNEXURE-2

Instrumentation & Control

[4 Pages excluding cover sheet]

TC-CN-024-17-EN (MOC-1405)
 172-JB-L-0600 & 172-JB-L-0602

172-JB-L-0600
172-JB-L-0602

Spare terminals in TB and

spare pair of main cable
shall be used.

MQAE010-1000-40ER-0001_ANNEXURE-2 – I&C Figure-1

 172-JB-L-0700 & 172-JB-L-0702

172-JB-L-0702
172-JB-L-0700

Spare terminals in TB and spare

pair of main cable shall be used.
MQAE010-1000-40ER-0001_ANNEXURE-2 – I&C Figure-2
 172-JB-L-0800 & 172-JB-L-0802

172-JB-L-0800
172-JB-L-0802

Spare terminals in TB and spare pair of

main cable shall be used.

MQAE010-1000-40ER-0001_ANNEXURE-2 – I&C Figure-3

 172-JB-A-0606, 172-JB-A-0706 & 172-JB-A-0806

172-JB-A-0706
172-JB-A-0606 172-JB-A-0806

Spare terminals in TB and spare pair of

main cable shall be used.

MQAE010-1000-40ER-0001_ANNEXURE-2 – I&C Figure-4