Computational pipeline monitoring
Real-time comparison of metered flow against a hydraulic model across 420 km of export line; calls a leak down to 0.6% of throughput.
Innovation
Digitalisation
Instrumentation, models and automation deployed where they change an operating decision — and nowhere they do not.
Falaj's digital programme is deliberately narrow. We build or buy where a tool changes what an operator, planner or engineer actually does, and we decline the rest. Three-quarters of the programme's spend sits in condition monitoring, hydraulic and reservoir modelling, and the integrity systems on the pipelines.
The single largest return has come from the least glamorous item: metering. Once every flare tip was metered rather than estimated, the mitigation priority order changed completely and two fields turned out to be responsible for more than half the group total.
What is deployed today
Condition-based maintenance
Vibration, thermography and lube analysis on rotating equipment at all operated plants, replacing calendar-based overhauls on roughly 60% of the machine list.
Continuous methane detection
Fixed optical gas imaging at processing sites and quarterly aerial survey across the fields, feeding a single leak detection and repair register.
Digital twin of the Rish Dune plant
A validated process model used for operator training, shutdown rehearsal and debottlenecking studies before anything is changed on the running plant.
Reservoir model refresh cycle
Full-waveform seismic inversion and quarterly history matching, which is what exposed the under-drained northern flank at Al Nakhil.
Integrated planning
One production, maintenance and logistics plan per asset rather than three that disagree, updated weekly.