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PETRONAS Sep-iSYS: Integrated Separation System for Slug, Sand, Inlet Heating and 3 Phase Separation
DD Technology 2 July 2012Council nd Date: 2 July 2012 Time: 9.00am 5.00pm Venue: Meeting Room, Level 23, PeTT 1
2012 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
Objective
To seek DDTC endorsement to: 1) Adopt PETRONAS Sep-iSYS Integrated Separation System as a standard inlet separation system for PETRONAS Carigali Sdn. Bhd. 2) Implement Sep-iSYS at new and existing facilities
Since its first installation in August 2011, Sep-iSYS has demonstrated the following benefits
CAPEX REDUCTION:
Up to 50%
REDUCTION IN FOOTPRINT AND WEIGHT
Up to 50%
Online sand flushing and cleaning facilities
No liquid carry over due to steady inlet flow Stable flow during slugging and minimum pressure drop Breaking down the emulsion before the liquid enters the separator
Background
Sep-iSYS is a proprietary inlet separation technology developed by PETRONAS, with a patent filed on 31 January 2011. In July 2011, PETRONAS MC endorsed the commercial arrangement for SepiSYS and a Joint Commercialisation Agreement between PETRONAS Technology Ventures Sdn. Bhd. and NGLTech was executed. First unit installed in TGT FPSO for HLJOC, Vietnam and has been in continuous operation since August 2011.
Second unit being fabricated for D1 FPSO ONGC in India. First oil in December 2012.
Sep-iSYS technology was launched during WGC 2012, by PETRONAS COO, Datuk Wan Zulkifli as PETRONAS Technology Product
COMMON ISSUES:
Complex internals not suitable for waxy/fouling service Complex sand handling capability High pressure drop
Gas Outlet
Gas Cooler
Inlet Separator Inlet Heater
Water Outlet
2nd Heater
Oil Outlet
Compressor
Cooler Inlet
Scrubber
Slug Catcher
LC LC
Separator Heater
LC
Water Outlet
Integrated gas, liquid and sand separation with high efficiency Compact system thus reducing overall size, weight, equipment and controls
Scrubber
2
Separator Separator Separator
Sand Collector
Increase availability due to online flushing system Protects downstream system from liquid carry over and oil/water slip through Energy efficient system Suitable for motion sensitive facilities and for handling waxy and fouling fluid
2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
Scrubber
Water Outlet
Oil Outlet
Production Inlet
Gas Outlet
h1 Scrubber
RO
Sand Collector
Water Outlet
Oil Outlet
9
Gas Outlet
h1 Scrubber
RO
Liquid Flow
Water Outlet
Oil Outlet
10
Key Advantages
OPERABILITY ADVANTAGES
Large Slug handling Capacity Suitable for waxy and fouling fluids Negligible pressure loss low compression power Stable liquid heating for emulsion breaking
DESIGN ADVANTAGES
Compact and light weight Minimal instrumentation Minimal separator internals in bulk liquid separator
The first unit of Sep-iSYS was installed on TGT FPSO for HLJOC in Vietnam and has been in continuous operation since August 2011.
Separator and Scrubber installation Slug Catcher/Expended Pipe installation
TECHNICAL REQUIREMENT
Max Oil
Max Water Max Liquid Max Gas Slug Handling
Te Giac Trang
Jan 2003 16-1 Oil/ Gas 45 m/ 149 ft
55,000 bopd
75,000 bwpd 130,000 blpd 120 mmscfd 70 m3
TGT FPSO
Oil Hoang Long Production since 2011
13
14
Realized weight savings of 53% and cost savings of 56% versus conventional separation system for TGT Vietnam
WEIGHT SAVINGS: COST SAVINGS:
53%
398 tons
Structural Piping & instrumentation Inlet Heater Scrubber
56%
4.55 mill
Structural Piping & Instrumentation Separator Internals Inlet Heater Scrubber Separator Slug Catcher
192 tons
Separator
Slug Catcher
1.98 mill
Savings :
Conventional
Sep-iSYS
Conventional
Sep-iSYS
15
Inlet Monitoring
16
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Realized weight savings of 47% and cost savings of 49% versus conventional separation system for ONGC
WEIGHT SAVINGS: COST SAVINGS :
47%
186 tons
Structural Piping & Instrumentation Inlet Heater Scrubber Separator Expended Pipe
49%
2.23 mill
Structural Piping & Instrumentation Inlet Heater
Savings :
Conventional Sep-iSYS Conventional
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TECHNICAL REQUIREMENTS
Crude from wellhead gas from BEP-A
Total Liquid Oil Total Oil Associated Gas Slug Volume 130,000 blpd 30,000 bopd 130 mmscfd 15 m3
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Conventional
Sep-iSYS
22
Simulated weight savings of 52% and reduction in number of equipment of 55% versus conventional separation system for BOCPP
WEIGHT SAVINGS: COST SAVINGS:
52%
386 tons 147 tons
Level Transmitters/Gauges Associated Piping Crude Transfer Pump Sep-iSYS Separator B Separator A Slug Catcher
55%
6.4 mill
Structural Associated Piping Controls & Instrumentation Crude transfer Pump Scrubber Separator Internals Sep-iSYS Separator Slug Catcher
186tons tons 69
3.58 mill
Conventional Conventional
Sep-iSYS
Sep-iSYS
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Up to 50%
REDUCTION IN FOOTPRINT AND WEIGHT
Up to 50%
Online sand flushing and cleaning facilities
No liquid carry over due to steady inlet flow Stable flow during slugging and minimum pressure drop Breaking down the emulsion before the liquid enters the separator
24
Recommendation
To seek DDTC endorsement to: 1) Adopt PETRONAS Sep-iSYS Integrated Separation System as a standard inlet separation system for PETRONAS Carigali Sdn. Bhd. 2) Implement Sep-iSYS at new and existing facilities
25
Next Steps
To consult with PCSB Project Managers to identify requirements for Sep-iSYS at existing and future facilities. To conduct feasibility study on requirements.
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THANK YOU
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BACKUP SLIDES
28
Cost Estimate Basis (installed) Separator Scrubber Inlet Heater Associated Piping Instrumentation Structural Slug Catcher Vessel Expanded Pipe (Sep-iSYS)
30
Size Comparison
Slug Catcher Separator Scrubber Inlet Heater Conventional 4.0m x 16m 3.0m x 12.4m 2.2m x 4.5m 1.7 x 8m Conventional 2.7m x 10m 3.4m x 10.8m 2.0m x 4.0m 1.5 x 9m Conventional 2.7m x 6m 4.0m x 14m 4.0m x 14m Sep-iSYS 1.5m x 30m 2.2m x 9.0m 1.8m x 3.2m 1.5 x 6m Sep-iSYS 1.5m x 6.0m 2.6m x 9.0m 1.8m x 3.2m 1.5 x 6m Sep-iSYS 1.5m x 8.5m 3.7m x 14m 1.8m x 3.2m
TGT
ONGC
BOCPP
31
To Compression Trains
60 34
Polishing Scrubber
RO
2.0m(ID) x 2.2m(H) 10
3.7m(ID) x 14m(L)
20
Separator
10 14
PW System
Crude to BOP-A
To PW Degasser
2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
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14
Slug Catcher
42
To Compression Trains
2.7m(ID) x 6m(L)
28 28
Crude BODP-B FWS BODP-C FWS BODP-E FWS BOJT D-2 FWS BOJT D-1 FWS BODP-A & BODP-C
24
LP Separator A
24
LP Separator B
4m(ID) x 14m(L)
10
Crude to BOP-A
10
PW System
To PW Degasser
33
OTHER SLIDES
34
PCSB operation facilities with liquid carry-over experience based on GTS capacity check on separator performance:
PMO ABU PMO Resak PMO Duyong SKO West Lutong SKO Baram SKO Bokor SKO Baronia GTS is currently working on capacity check for PMO Dulang & Angsi, SBO-Sumandak
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Sep-iSYS Applications
All inlet separation systems, particularly those experiencing heavy slugging Deep-water developments
FPSOs
Systems handling waxy/fouling fluid
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D1 FPSO for ONGC in India. Presently being fabricated and will be operational in December 2012. System designed for the following specifications:
Max Oil Max Water Max liquid Max Gas Handling Slug Handling Capacity = 50000 bopd = 50000 bwpd = 100000 blpd = 10.6 MMscfd = 10 m3
2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
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