Project Overview:
PDO (Petroleum Development Oman) launched the "KGP & SNGP Fire Water System Project" to upgrade its active fire protection systems. The EPC (Engineering, Procurement, and Construction) contract was awarded to Worley Parsons-Arabian Industries JV, Oman. The scope of 3D modeling and stress analysis for the downstream piping of the deluge skids was subcontracted to Tyco Limited Co LLC, Oman. Elixir Engineering was tasked with the design, engineering, and 3D modeling of the fire water piping network downstream of the deluge valves.
Project Facilities:
- Firewater Storage Tanks (T-86001/2): Two tanks, each with a capacity of 4,780 m3, provide water for firewater pumps. These tanks can supply water for up to six hours of peak firewater demand (795 m3/hr). They are filled via tankers, which come equipped with unloading pumps. The tanks operate on a rotating maintenance schedule, ensuring one tank remains online while the other undergoes maintenance.
- Firewater Pumps (P-8601/P-8602): Two pumps, one electric motor-driven and one diesel engine-driven, each with a capacity of 795 m3/h, operate in a 1 working, 1 standby configuration. The electric pump is the duty pump, while the diesel pump is on automatic standby. The firewater pump automatically activates when ring main pressure drops to 750 kPag and runs until manually stopped.
- Jockey Pumps (P-8603A/B): Two jockey pumps (15 m3/hr capacity each) maintain the ring main pressure between 800 and 850 kPag. One jockey pump operates automatically, while the other remains on manual standby.
- Ring Main Headers: Two ring main headers distribute firewater across the facility. The firewater system includes various hydrants, monitors, and fixed foam systems, which protect the condensate holding tank at KGP & SNGP.
- Instrumentation & Biocide Injection: Control valves use instrument air supplied by existing IA skids. Biocide chemicals are batch-injected into firewater storage tanks to prevent bacterial growth, using either solid tablets or hypochlorite solutions.
Execution Methodology:
Review of Design and Process Parameters:
- Reviewed P&ID for both KGP and SNGP networks.
- Verified and revalidated water demand calculations for the firewater network.
- Prepared Piping and Valve Material Specifications based on project requirements.
Piping Design and Wall Thickness Calculation:
- Conducted pipe wall thickness calculations according to project specifications.
- Created a comprehensive line list for both networks, ensuring all specifications were met.
3D Modelling in PDMS:
- Updated the existing 3D model using PDMS (Plant Design Management System).
- Developed initial pipe routing, ensuring full coverage of sprinklers, fire hydrants, and foam systems.
- Prepared support drawings and support schedules for critical piping arrangements.
Pipe Stress Analysis in CAESAR II:
- Modeled pipes using CAESAR II for various load conditions, including:
- Thermal loads
- Sustained loads
- Hydrostatic pressure
- Occasional loads (e.g., wind and wave parameters)
- Transportation loads
- Verified pipe load values, deflection, and stress levels to ensure they met allowable limits. Adjustments to routing and support arrangements were made where necessary.
- Considered skid nozzle loads and finalized anchor points both inside and outside the skid based on nozzle loads.
Validation and Review:
- Participated in 3D model reviews at 30%, 60%, and 90% stages.
- Ensured clash-free design through careful review and coordination of all piping networks with other structures.
- Submitted all piping load values to the structural team for integrity checks
Support and Vendor Coordination:
- Provided ongoing support for vendor queries during the procurement phase.
- Assisted in the creation of an As-Built 3D Model based on redline markups provided by the client.
Deliverables:
- Pipe Wall Thickness Calculation
- Pipe and Valve Material Specifications
- Line List
- Primary and Secondary Support Schedules
- Piping Stress Analysis Report
- General Arrangement (GA) Drawings
- Piping Isometric Drawings
- Sprinkler Coverage Drawings
- Pipe Spool Drawings
- Bulk Material Takeoff (MTO)
- Painting Specification
- Transportation Philosophy
Project Highlights:
- Successful completion of pipe stress analysis under various load conditions.
- Ensured compliance with all client specifications and industry standards.
- Delivered a clash-free 3D model, incorporating design reviews at every stage (30%, 60%, and 90%).
- Provided comprehensive support, from design validation through procurement and construction phases.
By leveraging advanced 3D modelling techniques in PDMS and CAESAR II pipe stress analysis, Elixir Engineering delivered a fully optimized, reliable firewater system, ensuring fire protection at both KGP & SNGP facilities.
