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NAE DEEP OFFSHORE PROJECT ETAN FPSO EQUIPMENT SIZING / VALIDATION REPORT CD-FE 01 01/04/2014 Issued

NAE DEEP OFFSHORE PROJECT

ETAN FPSO

EQUIPMENT SIZING / VALIDATION REPORT

CD-FE

01

01/04/2014

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exploration & production

 

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  XXX-IES-P-DOC-001

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INTERNATIONAL ENERGY SERVICES LTD.

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ABSTRACT

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TABLE OF CONTENTS

LIST OF TABLES

5

LIST OF APPENDICES

5

LIST OF ABBREVIATIONS

6

1.0

INTRODUCTION

7

1.1

PROJECT OVERVIEW

7

2.0

OBJECTIVES

8

3.0

PUMP SIZING

9

3.1

PUMP SIZING CRITERIA

9

3.2

FLUID PROPERTIES

10

3.3

ASSUMPTIONS

11

3.3.1

PRODUCED WATER TRANSFER PUMP

11

3.3.2

WATER INJECTION BOOSTER PUMPS

11

3.3.3

WATER INJECTION PUMPS

11

3.4

CALCULATION PROCEDURE

12

4.0

RESULTS / EVALUATION

13

5.0

CONCLUSION

14

6.0

REFERENCES:

15

APPENDICES

16

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LIST OF TABLES

Table 1

Equipment Index

Table 2

Liquid line sizing for pump suction & discharge

Table 3

Fluid Properties

Table 4

Summary of Results

LIST OF APPENDICES

Appendix I

Produced water pump sizing calculation

Appendix II

Water Injection Pumps Sizing Calculation

Appendix III

Heat & Material Balance For Maximum Oil & Gas (Start-up)

Appendix IV

Heat & Material Balance For Maximum Water Case

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LIST OF ABBREVIATIONS

Abbreviations

Meaning

bara

Bar absolute

barg

Bar guage

bpd

Barrels per day

FEED

Front End Engineering Design

FPSO

Floating, Production, Storage & Offloading

HMB

Heat & Material Balance

hp

Horse power

IESL

International Energy Services Limited

Kg/m3

Kilogram per cubic metre

kW

kiloWatts

NAE

Nigerian Agip Exploration Ltd

NPSHA

Net Positive Suction Head Available

NPSHR

Net Positive Suction Head Required

P&ID

Piping & Instrumentation Diagram

psi

Pound per square inch

SNEPCo

Shell Nigeria Exploration & Production Company

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1.0 INTRODUCTION

1.1 Project Overview Nigerian Agip Exploration Limited (NAE) and Shell Nigeria Exploration and Production Company (SNEPCo) are in the process of developing NAE Deep Offshore Block located approximately

150kilometers offshore Nigeria. In particular, the block is a 1,958 km 2 block license located in the deepwater eastern portion of the Niger Delta in Nigeria, with water depths ranging from 1,200 to 2,400

m.

The current development scenario involves production from subsea wells located in water depths around 1,750 - 1800 meters. The wells would be conveyed to a moored ship-shaped FPSO. The

FPSO would be utilised for:

a. Stabilisation, dehydration, storage and export of crude oil product,

b. Dehydration, compression and export of gas,

c. Separation and treatment of produced water,

d. Seawater treatment;

e. Produced water and Seawater injection for Reservoir pressure maintenance

f. Power generation for FPSO marine, accommodation and process loads,

g. Gas lift at riser base at an appropriate pressure

The block (Fig. 1) comprises two discoveries, Zabazaba and Etan, which are separated by a significant seafloor canyon. The field is in about 1,950 m water depth and the distance between Zabazaba and Etan is about 30/40 km.

the distance between Zabazaba and Etan is about 30/40 km. Figure 1: Block Location This document

Figure 1: Block Location

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BW Offshore has therefore employed the services of IESL to carry out the Front End Engineering Design

(FEED) for the new Water injection and Produced Water Treatment modules/systems.

This document shows the process equipment sizing calculations carried out on the Produced Water

Treatment and New Water Injection modules.

2.0 OBJECTIVES

The purpose of this document is to provide the sizing calculations for the both the Produced Water and

Water Injection Pumps.

Table 1: Equipment Index

No.

Description

Tag

Quantity

P&ID Number(s)

   

44PA101A/B/C

   

1

Produced Water Transfer Pump

(3x50%)

3

4295-IES-P-XB-44005.001

   

29PA101

   

2

Water Injection Booster Pumps

A/B/C (3x50%)

3

4295-IES-P-XB-29004.001

3

Water Injection Pump

29PA102 A / B

2

4295-IES-P-XB-29005.001

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3.0 PUMP SIZING

3.1 Pump Sizing Criteria

The Water injection and injection booster pumps were sized in accordance with API RP 14E (Ref 8)

and the Eni exploration & production design criteria reference document for process minimum

requirement (Ref 9).

The following criteria form the basis for the pump sizing as per API 14E (Ref 8):

Velocity in the suction pipe shall be between 2 - 3 ft/s (Table 2.3).

Velocity in the discharge pipe shall be between 6 – 9 ft/s (Table 2.3).

Pump should be sized to provide adequate head required and to ensure that the NPSHA exceeds

the NPSHR (Ref 8) so that essentially no vapor will be flashed from the liquid as it enters the pump

casing or cylinder.

Similarly, Table 2 below shows the design criteria as specified in the Eni exploration & production

design criteria.

Table 2: Liquid line sizing for pump suction & discharge

 

P(bar) / 100m

 

Normal (Note 1)

Maximum (Note 1)

Maximum

 

SERVICE

Velocity

     

(m/s)

Pump Suction

     

Liquid @ bubble point or with dissolved

0.05

0.8

1.0

gas ( 4”)

Liquid at bubble point or with dissolved

0.07

0.1

1.5

gas ( 4”-8”)

0.07

0.11

1.8

Liquid at bubble point or with dissolved

gas ( 8”)

Sub-cooled Liquid ( < 8”)

0.25

0.35

2.0

Sub-cooled Liquid ( 8”)

0.25

0.35

3.0

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Table 2: Liquid line sizing for pump suction & discharge (Cont’d)

∆P(bar) / 100m Maximum Normal (Note 1) Maximum (Note 1) SERVICE Velocity (m/s)
∆P(bar) / 100m
Maximum
Normal (Note 1)
Maximum (Note 1)
SERVICE
Velocity
(m/s)

Pump Discharge

Lines ( < 4”)

Lines ( 8”)

0.05

0.07

0.8

0.1

1.0

1.5

Note 1: For all calculations, reference was made to the normal value.

3.2 Fluid Properties

The fluid properties for the Produced Water Transfer Pumps was taken from the Maximum Water

Simulation case, while the fluid properties for the Water Injection Booster pumps and Water Injection

pumps were taken from the Maximum Oil & Gas (Start-up) Simulation case.

The table below shows the fluid properties from the respective Heat and Material Balance (HMB)

Tables (Ref 4 & 5) which were used for the sizing.

Table 3: Fluid Properties

No.

Description

Tag

Flowrate

Flowrate

Density (Kg/m 3 )

(m

3 /h)

(bpd)

 

Produced water

44PA101A/B/C

     

1

transfer pump

(3x50%)

198.72

30,000

994.4

2

Water injection

29PA101 A/B/C

132.40

20,000

1006

booster pumps

(3x50%)

3

Water injection pump

29PA102 A / B (2 x 100%)

264.80

40,000

1006

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3.3

ASSUMPTIONS

Assumptions were made on individual pump sizing which await the actual values from the isometric drawing. Below are the series of assumptions.

3.3.1

Produced water transfer pump

Suction pipe length 10m

Suction static head

8m considering the vessel height.

Total K-factor (based on valves & fittings on the suction line) 6.89

Discharge pipe length based on 100ft (30.48m)

Discharge static head 10m

Total K-factor (based on valves & fittings on the discharge line) 2.89

3.3.2

Water Injection booster pumps

Suction pipe length 10m

Suction static head 8m

Total K-factor (based on valves & fittings on the suction line) 1.33

Discharge pipe length 10m

Discharge static head 10m

Total K-factor (based on valves & fittings on the discharge line) 4.74

A discharge pressure of 11 barg was used.

3.3.3

Water Injection pumps

Suction pipe length 10m

Suction static head 8m

Total K-factor (based on valves & fittings on the suction line) 0.637

Discharge pipe length 20m

Discharge static head 10m

Total K-factor (based on valves & fittings on the discharge line) 2.38

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3.4 CALCULATION PROCEDURE

The following methodology was used in performing the pump sizing / NPSH calculation

a. Pipe Data & Fluid properties was gathered

b. The absolute total pressure at pump suction was calculated.

c. The absolute total pressure at pump discharge was calculated.

d. The Differential head of the pumps was determined.

e. The pump hydraulic power was determined.

f. The pump actual horse power was determined.

g. The Net Positive Suction Head Available (NPSHA) was calculated.

Appendix I & II shows the detailed pump sizing calculation of the Produced Water transfer pumps, Water Injection Booster Pumps and Water Injection Pumps.

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4.0 RESULTS / EVALUATION

A summary of the calculation result is giving in the table below.

Table 4: Summary of Results

 

Produced Water

Water Injection

Water Injection

Pump Parameters

Transfer Pump

(44PA101A/B/C)

Booster Pump

(29PA101A/B/C)

Pump

(29PA102A/B)

Differential Head (m)

28.668

84.068

1407.640

Flowrate (bpd)

32,998*

20,000

40,000

Hydraulic Power (hp)

22.73

40.85

1371.19

Estimated Horsepower (kW)

19.51

35.60

1165.01

NPSHa (m)

37.84

48.02

128.99

Pump Efficiency

85.64

83.72

86.31

P / 100m (bar)

Suction

0.02

0.025

0.025

Discharge

0.18

0.294

0.237

Velocity

Suction

0.84

0.7

0.8

(m/s)

Discharge

2.06

2.0

2.2

The pressure drop per length (P / 100m) values were obtained from the Process Calculation Report

(Ref 10) which captured all process lines inclusive of all pump suction and discharge lines.

*A flow margin of 10% was added to the produced water pumps.

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5.0

CONCLUSION

The results obtained from the pump sizing calculation as shown in Table 4, indicates that the pump suction and discharge lines for the Produced Water transfer pumps, Water Injection Booster Pumps and the Water Injection pumps adequately meet the specified criteria in section 3.1. Appendix I & II show the detailed sizing calculation spreadsheets of the Produced and sea water pump sizing respectively.

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6.0

REFERENCES:

1. Basis of Design Etan Development - 325300BGRB12000.

2. Process Design Philosophy - 4295-BWO-P-FD-00001.

3. Produced water transfer Pumps P&ID – 4295-IESL-P-XB-44005.001.

4. Heat & Material Balance for Maximum Oil & Gas (Start-up).

5. Heat & Material Balance for Maximum Water Case.

6. Water injection booster pumps P&ID - 4295-IES-P-XB-29004.001.

7. Water injection pumps P&ID – 4295-IES-P-XB-29005.001.

8. API 14E – Recommended Practice for Design & Installation of Offshore Petroleum Production Platform Piping Systems (Section 2.3b).

9. Eni Exploration & Production Design Criteria (10009.HTP.PRC.PRG) – Process Minimum Requirement

10. Process Calculation Report (XXX-IES-P-DOC-002)

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APPENDICES

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APPENDIX I

Produced water pump sizing calculation

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APPENDIX II Water Injection Pumps Sizing Calculation

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APPENDIX III Heat & Material Balance For Maximum Oil & Gas (Start-up)

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APPENDIX IV Heat & Material Balance For Maximum Water Case

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