This area of investigation was directed toward addressing the impact of specific equipment issues on the Safaniya Utility Units’ Asset Management Program. The issues outlined below are those which the Safaniya staff expressed concern and those which the Intertek team determined should be addressed. They should not be construed as being the only specific equipment issues that should be addressed by Safaniya staff. Tables 3-12 through 3-15 list the issues addressed in the following areas:
• Rotating Machinery
• Static Equipment/Piping
3.9.1 Rotating Machinery
This area of investigation was directed toward addressing the impact of rotating equipment issues on the Safaniya Utility Units’ Asset Management Program. Table 3-12 lists the issues addressed and the resultant findings:
ROTATING EQUIPMENT ISSUES
|Equipment Item||Equipment Item|
|G26-G-255C/D||• They are failing due to corrosion from the RO water from the Tanajib Plant which has high oxygen content.
• The corrosion is eating the close clearance parts causing high recirculation and overloading the motor.
• The corrosion also affects the piping feeding the new formation water injection and booster pumps; the seals in these pumps are experiencing problems.
|G26-G-1412 A/B/C/D and G26-G-1413 A/B/C/D||The Formation Water Booster and Injection pump seals experienced the same corrosion issues affecting the Seal Pumps.|
|G26-G-1412 A/B/C/D||Grout preparation for the pumps did not follow industry practice. It was prepared in a wheel barrel. Inspection indicates that it was starting to crack, with oil seeping into the cracks.|
The key finding from the Rotating Equipment area is summarized as follows:
The current major machinery issue in Utility Plant G 26 is frequent failure of the new seal flush pumps, G26-G-255C/D, and the new formation water injection and booster pumps, G26-G-1412 A/B/C/D and G26-G-1413 A/B/C/D.
They are failing due to corrosion from the RO water from the Tanajib Plant which has high oxygen content. To address the seal problem, replacement of the present mechanical seals with double seals with a recirculating flush of potable water has been proposed. This is a viable solution for this problem. In addition, the proposed design change to obtain the RO water downstream of the deaerator at Tanjib should solve the corrosion issue caused by oxygen content in the process stream.
3.9.2 Static Equipment/Piping
This area of investigation was directed toward addressing the impact of Static Equipment and Piping issues on the Safaniya Utility Units’ Asset Management Program. Table 3-13 lists the issues addressed and the resultant findings.
STATIC EQUIPMENT / PIPING EQUIPMENT ISSUES
|Formation Water Lines||Internal Corrosion in the line: The line is internally (Fusion Bonded Epoxy (FBE) lined. Internal corrosion is at locations where the line is welded. The piping was purchased in long lengths, and therefore had to be cut correct lengths for spools. The spools were welded which resulted in loss of epoxy lining, exposing the steel surface for corrosion.|
|Washwater Lines||Internal corrosion in the lines is caused by dissolved oxygen, and occasional low pH of 5.5. As the water produced does not meet the needs, additional water is imported from Tanajib. The dissolved oxygen is supposed to be <10 ppb, but the water from Tanajib has about 5 ppm with occasional low pH of 5.5|
|E-310A/B/C Boiler Tubes||Internal corrosion of boiler tubes was caused by lack of proper water treatment resulting in scaling, cracking at
tube-to-tubesheet welding due to uneven expansion during heating, and under deposit pitting.
|Washwater Line Flange Connections||The leaks were caused by uneven placement of the metal gasket and improper bolt tightening on the gasket resulting in crimping.|
The key findings from the Static Equipment/Piping area are summarized as follows:
• The formation water line corrosion issue is caused by welding in new spool pieces which results in damaged FBE lining. Recommendation: Damaged piping should be replaced with new spools using flanged connections.
• The Washwater Lines internal corrosion in the lines is caused by dissolved oxygen. As with the seal flush pumps, the solution to this problem is the proposed design change to obtain the RO water downstream of the deaerator at Tanajib.
• Internal corrosion of boiler tubes was caused by lack of proper water treatment resulting in scaling, cracking at tube-to-tubesheet welding due to uneven expansion during heating, and under deposit pitting. This has been corrected by the change of the water treatment vendor and changed chemical treatment.
• A Washwater Line Flange Connection issue which arose because of improper bolting.
Recommendation: This issue can be addressed by training mechanics in the development and application of bolting procedures, training personnel in their proper application, and proper quality control of bolting maintenance tasks.
This area of investigation was directed toward addressing the impact of Instrument issues on the Safaniya Utility Units’ Asset Management Program. Table 3-14 lists the issues addressed and the resultant findings.
|PCV-2066B/2067B and PCV-2068B, ratio control valve for E-310A/B/C.||Pneumatic controllers should be used to operate these valves but it’s not working automatically.|
|Fire & Gas Detection system||Siemens VESDA system is in operation to detect fire and gas in the plant. This system, though adequate, is old technology and should be upgraded to a system with addressable devices. Safaniya is undertaking system upgrade under BI-747.|
|Missing Tag Number plates on field instruments, e.g., no tag found on Yokogawa transmitter installed near 26-G-312||Missing tag numbers could potentially result in improper maintenance and/or inadvertent operation that could impact safety or production.|
The key finding from the Instrument area is summarized as follows:
• Operation of PCV-2066B/2067B and PCV-2068B, and the ratio control valve for E-310A/B/C is accomplished manually which is not an optimum practice. Recommendation: The root cause of the loss of automatic control should be determined and the problem corrected.
This area of investigation was directed toward addressing the impact of Electrical equipment issues on the Safaniya Utility Units’ Asset Management Program. Table 3-15 lists the issues addressed and the resultant findings.
ELECTRICAL EQUIPMENT ISSUES
|Signs of trace oil leakage were observed at the Sub-12 for the 230/13.8kV Power Transformer. Equipment Tag: G26-P-101T 60/80MVA||Oil leakage may indicate onset of potential failure or impact the effectiveness of the transformer.|
|Nameplates at nearby motors G26 EM-22 are already not visible due to corrosive action on the metallic nameplates.||Inability to review nameplate data could lead to improper maintenance a|
|Corrosion effects are visibly found on the skids and frames and enclosures of the equipment.||Corrosion within enclosures could affect the operability of electrical equipment|
|Some cable routing markers are not already visible, as marking are not available.||Lack of marking could lead to misidentification of cables.|
|Old Electromechanical Relays are still observed and used on the SS-12 substation.||Obsolescence of the Equipment is based on the document to be provided by Mr. Ali. The document was not provided. The Saudi Aramco corporate team accompanying the Intertek team subsequently indicated that the obsolescence issue is part of their running activities. In cooperation with other Aramco organizations, there is an ongoing Electrical Equipment Live Age program that evaluates the equipment obsolescence and the adequacy for being maintained in operation.|
|Some grounding cables (bare copper) are showing signs of corrosion due harsh environment near the shoreline.||Corrosion could lead to a break in the cable|
|On the old installations it was observed that some conduits used PVC coated RGS to address and protect the system from Corrosion.||Paint coating was applied to conduits to provide protection from corrosion.|
The key findings from the Electrical equipment area are summarized as follows:
• Signs of oil leakage were observed at the 230/13.8kV Power Transformer G26-P-101T 60/80MVA may indicate onset of potential failure or impact the effectiveness of transformers. Recommendation: Insure that checking for transformer oil leaks is included as part of the equipment PM regime.
• Some grounding cables (bare copper) are showing signs of corrosion due to the harsh environment near the shoreline which could lead to a break in cables. Recommendation: Insulated grounding cables should be used to protect the cable conductors from the corrosive conditions of the unit.