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EPIC For Dukhan Production Facilities Upgrade (DPFU) Phase 1A-Pac…

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EPIC For Dukhan Production Facilities Upgrade (DPFU) Phase 1A-Package 1

Project

Quick Info

Countries: --
Basins: --
Project SDGs:
Includes Sustainable Development Goals from the project and its locations.
Integrated Water Resource Management (SDG 6.5)
Sustainable Production (SDG 12.4)
Project Tags:
Includes tags from the project and its locations.
Industrial Wastewater
Water Recycling and Reuse
Progress to Date: Project is still in the engineering phase. Expected handover “all stations” is by December 2022. The success of the project is measured by its performance guarantees, namely: 1. The reduction of the oil content in the water by up to 90%. 2. The reduction of the solid waste content in the water to 30 mg/l or less (100% of particles >=10micron).
Services Needed: Other
Stakeholder engagement & facilitation
Desired Partners: NGO / Civil Society
UN Entity
Language: English
Start & End Dates: Nov. 01, 2019  »  Ongoing
Contextual Condition(s): REGULATORY: Water-related product or operational standards
Additional Benefits: Other
Beneficiaries: Manufacturers
Planning & Implementation Time: More than 3 years
Financial Resources: More than $500,000 USD
Primary Funding Source: corporate
Project Challenges: Other
Project Source: User
Profile Completion: 90%

Project Overview

To provide state of the art produced water treatment plants at 7No stations as part of the client’s multi-stage, long-term upgradation plan. The purpose of the plant is the treatment of Produced water heavily contaminated (a by-product of the oil production) and reduce its high content of oil and suspended solids to enable its recycle and reuse. The project integrates a number of filtration and separation technologies supplied by world leading firms to meet the high standard…

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To provide state of the art produced water treatment plants at 7No stations as part of the client’s multi-stage, long-term upgradation plan. The purpose of the plant is the treatment of Produced water heavily contaminated (a by-product of the oil production) and reduce its high content of oil and suspended solids to enable its recycle and reuse. The project integrates a number of filtration and separation technologies supplied by world leading firms to meet the high standards set by the client. Oil that is separated from the water is recovered and processed by for industrial purposes. Contaminated solids are captured and transported to a separate facility specialized in the treatment of hazardous waste. The treated water presents a much safer option for the environment and underground waters due to its significantly reduced content of harmful substances. The R&R (recycle & reuse) concept also eliminates the need to depend on water from any natural resources for the operations of the client. The plant does not discharge any harmful emissions to the environment.

Black Cat has marked 1 million man-hours without a lost-time injury (LTI) & Achieved First Milestone by safe Completion of Sector 1 Tie-Ins during Shutdown at Dukhan Production Facilities Upgrade Phase 1 A-Package 1.99% of Engineering has been completed and overall progress of 44.6%

In addition, the DPFU project shall provide the following:

  1. A combined treatment capacity of up to 107,160 cubic meter of produced water per day (including 160.8 cubic meter of contaminated oil per day) for all the seven stations.
  2. Oil recovery of 152.8 cubic meters per day from the treated water per day.
  3. Finally, a total weight of 100 tonnes of hazardous solid contamination shall be removed from the treated water per day.

Unintended Consequences

Not Applicable

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Basin and/or Contextual Conditions: REGULATORY: Water-related product or operational standards
Project Benefits: Other
Indirect or Direct Beneficiaries: Manufacturers
Months & Implementing: More than 3 years
Financial Resources: More than $500,000 USD
Primary Funding Source: Corporate funding
Challenges: Other

Missed Opportunities

Project is ongoing therfore not applicable at this time

Unintended Consequences

Not Applicable

Project Narrative

Provision of Produced water primary treatment systems (de-oiling hydrocyclones) to improve separation of oil in produced water: 1. Provision of new De-oiling Hydrocyclones at KN, and KS, including all new associated facilities, and demolition of existing uncoated Produced water piping. (Currently there are no hydrocyclones at KN, and KS). 2. Replacement of existing De-oiling Hydrocyclones at FM, and KM by utilizing existing skid piping, supporting structures, and skid foundation. 3. Replacement of existing De-oiling hydrocyclones at FN, FS, and addition of one additional hydrocyclone at each station utilizing existing skid piping, supporting structures, and skid foundation Provision of new Produced water secondary treatment (PWST) systems at each of the seven degassing stations, KN, KS, KM, FN, FM, FS, and JM. Treatment systems include Induced gas floatation, Nut shell filters, Decanting / settling tanks, centrifuge systems, and centralized drying bed facility. In addition, various in plant modifications to suit the required flow rates such as Recovered oil tank pumps replacements at KS, KN, and various controls modifications at KS, KN, KM, FN, FS, FM, and JM. PWST systems shall be designed to meet specific water quality requirements stipulated in the Dukhan CTO, and QP reservoir engineering requirements. .Provision of Hot Oil Dump Coolers (Fin fan air cooled heat exchangers) at KN, KM, FM, and JM. The Proposed H.O. Dump Coolers are required to improve turn down requirements of existing hot oil system during low heat duty demand periods such as lower crude oil production rates in the future, and ambient temperature fluctuations. Provision of new flash K.O Drum, associated pumps and facilities at each of the seven degassing stations KN, KS, KM, FN, FM, FS, AND JM, for mitigation of existing burn pits.(Existing burn pits demolition is not part of this project requirements). DCS/ESD/F&G commons systems works including configuration of flow totalizer functions at each of gas lift manifolds stations for each gas lift manifold overall flow, each gas lift slot , and respective degassing stations/sector totalized flows Procurement of all equipment is over 78% complete. The project has entered the construction phase since Q1 2021. Below is a list of some of the activities currently ongoing at the seven stations: 1- Construction of the process tanks in the seven stations is ongoing. Water proofing, foundations backfilling and sand filling are in progress at various stages in each station. 2- Pumps skids foundations screeding completed. 3- Excavation underway for pipe rack foundations. 4- Excavation works for the foundations of the new floatation and filtration equipment ongoing. 5- Subgrade filling and compaction for access roads ongoing. 6- Installation of UPS systems at control room ongoing. 7- Earthing cable laying and termination in progress. 8- Separation equipment foundation casting completed in some stations and waterproofing ongoing. 9- Hydrotesting, painting, tagging ongoing at designated workshops for various piping spools etc. Project completion is planned for Q1 2023.

Partner Organizations


None found.

Boussaina Kalo Borchetta
Primary Contact  

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