Conceptual Design Report

7.1 SEPARATOR SIZING ASSIGNMENT

Design of a Horizontal vessel wire-mesh

Current proposal for the process facilities includes primary separator of 2.3m diameter
and 6m in length. The revised separator sizing and design is calculated below:

Part A: Minimum Area for Gas Demisting

For a droplet of liquid in the gas section of the separator, the drag force FD must be
lesser than the gravity force FG for the droplet to start falling down into the liquid
phase.

FG ≥ FD
Therefore QG ≤ λ
A

Therefore AGmin ≥ QG
λ

but QG is taken as the max allowed gas flow rate Q*max

Q*max = Qmax .  g  l   g 

Also Qmax=Qg x surge factor = 2.52 x 1.2= 3.024 (assumed Surge factor 1.2)

Therefore Q*max =3.024 x 5.2 0.5

= 2.43 x 10-1
810 – 5.2

Therefore, Minimum Area required for Gas de-misting Ag = 2.43 x 10-1

0.08
(λ = 0.08 for Horizontal separator)

Therefore Minimum Area for Gas demisting Ag = 3.038m2

But Ag= ПD2

0.5
8
Therefore D= 3.038 x 8 = 2.783m
П

Part B: Minimum Area For Liquid Degassing

The critical point at which a gas bubble will separate out into the gas phase occurs
when the buoyant force Fb equals and overcomes the gravity force Fg acting on the
bubble.
i.e. Fb ≥ Fg
Applying Stokes law (with the assumptions) to the resulting equations and resolving:

Vt = 2.18 x 10-8 ( l l- l g)
ηl

For optimum performance, the values of the oil parameters will be selected over water

Therefore Vt = 2.18 x 10-8 x (810-5.2) = 7.31x 10-3

2.4x10-3
Minimum Area for degassing, AL = QLmax/Vt

But QLmax = QL x Surge factor = 0.095 x 1.2 = 1.14x 10-1

Therefore AL = 1.14x10-1 = 15.61m2

7.31x10-3
Therefore the minimum area for liquid degassing is 15.61m2

Note L x D ≥ 4QL (To ensure bubble gets to the liquid surface)

П Vt

Therefore L ≥ 4QLmax = 7.13m

ПDVt

Part C: Inlet and Outlet Nozzle sizes

Cg= Vapor Volume__________________

(Vapor + liquid volumes at actual operating conditions)

Assuming flow time is constant at 1min.

Therefore, Volume of vapor=2.52m3 and volume of liquid=0.095m3

Cg=2.52/(2.52 + 0.095) = 0.96

Cg>0.85, therefore a Schoepentoeter will be used

m = (mg + ml)/ (Qg + Ql)

Vm= 4(Qg + Ql) cvb
di2

mg = ρgVg = ρgQg = 5.2 * 2.52 * 1.2 = 15.7248 kg/s

ml = ρlVl = ρoVo + ρwVw = ρoQo + ρwQw = (810 * 0.075 * 1.2) + (1000 * 0.02 * 1.2)
= 96.9 kg/s
m = (15.7248 + 96.9)/(2.52*1.2 + 0.095*1.2) = 35.84 kg per m3

For Schoepentoeter inlet, mVm2  8000

Vm2  (8000÷35.84)

Vm = 14.94m/s

But Vm= 4(Qg + Ql) ÷d12

d12 = 4(Qg + Ql)/(Vm = 4(2.615 * 1.2) / (3.142 *14.942)
d1=0.517m

For gas outlet nozzle gVg2  3750

Vg2 (3750÷5.2) = 721.153
Vg = 26.854m/s
Also dg2 = 4Qg/Vg = 4((2.52 * 1.2) / (3.142 x 26.854) = 0.1434
d2= 0.379m

Liquid outlet Nozzle

Liquid velocity  1m per sec.
Let Vl =4(Ql) ÷d32 = 1
d32 = 4(0.095*1.2)÷(3.142) = 0.147
d3=0.383m

Part D: Total volume required for level control

Assume time for gross liquid retention for control=120seconds

Slug time=5seconds
Operator response time=60seconds

0.5Vvessel = Vcontrol + Vsafe + Vbottom

Vcontrol =(S.F x Ql x Retention time) + (slug time x QT)

QT=Qg+QL=2.52 + 0.095=2.615

Vcontrol = (1.2 x 0.095 x 120) + (5x2.615) =26.755 m3

Vsafe=2 x S.F x operator response time x Ql =2 x 1.2 x 60 x 0.095=13.68m3

0.5Vvessel = 26.755 + 13.68 + Vbottom = 40.435 + Vbottom

To determine Vbottom
h* = h ÷ D
From notes, BTL-LL=0.25m, this implies that h=0.25m
And D=2.783m
h* = 0.25÷2.783 = 0.089

Locating the corresponding point for this value on the chart, Al* =0.045

But Al* Vl*

 Vl* = 0.045
V* = V ÷ Vvessel

Vbottom÷ Vvessel = 0.045

Vbottom = 0.045 Vvessel

Recall 0.5Vvessel = 40.435 + Vbottom = 40.435 + 0.045 Vvessel

Vvessel = 88.87m3
Also Vbottom = 0.045 Vvessel = 0.045x88.87 = 4 m3

Part E: Level control and Safeguarding points

From the reference page am assuming minimum values for the alarm and shutdown
points

From HH=0.5D
0.5Vvessel = Vcontrol + Vsafe + Vbottom

0.5D =hcontrol + hsafe + hbottom

Vsafe ÷ Vvessel = V*
V* = 13.68 ÷ 88.87 = 0.154
A* V*
A*hsafe = 0.154 and h* = 0.162

And hsafe = h* X D = 0.162x2.8 = 0.45m

hbottom = 0.25m

hcontrol = 1.4 – 0.45 – 0.25 = 0.7

LZA (LL) = 0.25m

LA (L) = 0.25 + 0.225 = 0.475m
LA (H) = 0.475 + 0.7 = 1.175m
LZA (HH) = 1.175 + 0.225 = 1.4m

To determine actual vessel length and diameter and comparing to separator diameter =
2.3m and length=6m in the notes.

From Diameter= (8 x Ag ÷) 0.5 = (8x3.038÷3.142) 0.5

D = 2.783m
From notes, the ratio of L to D must meet 2.5 < L÷D < 6
 Thus minimum length L =2.5.D = 2.5x2.783 = 6.96m
It implies that minimum volume =
0.25 x D2 x  x L = 0.25x3.142 x 2.7832 x 6.96=42.343m2

This volume differs from the Vvessel of 88.87m3

Thus actual length = (4*Volume) ÷ (3.142 * D2) = (4 * 88.868)÷(3.142 * 2.7832)
L=14.607m

L÷D = 14.43 ÷ 2.8 = 5.2 which is within the ratio band.

Hence the dimensions of the horizontal separator are: D=2.8m and L=14.43m

Recommended Separator sizing includes:

Length = 14.43m
Diameter = 2.8m
L to D Ratio = 5.2

7.2 WATER HANDLING FACILITIES – TREATMENT & DISPOSAL

Current proposed water handling facilities would discharge water into the sea with a
level of 40ppm oil (from the outlet of surge tank).

Below is a table showing the various Oil removal equipments for water treatment

Type Location Suspended Oil Size Production Disadvan

Oil content droplet Rate
(PPM) size
(Microns)
Skim Tank Onshore 50-100 Large Handle Requires l
not suitable large rates space
Plate Packs Onshore/ 30-50 30 Would Handle Increases
(Separators) offshore require large rates, separator
not suitable space to minimizes efficiency,
install distance reduces si
separators required for separator.
separation. Sensitive
slugs in th
feed.
Require sp
API Onshore 50-100 150 Large/Wide. Handle Insensitiv
Interceptor not suitable large rates variations
inlet flowr
Requires s
CPI/TPI Onshore 30-50 30 Modular but Handle Requires s
not suitable would large rates
require
space
Centrifuge Offshore 10-2 2 Compact, Small Can
not suitable small volumes accommod
modules small volu
can be skid only
mounted. Cost 10X
 hydrocyclo
Hydro Offshore 15-40 10 Compact, Can handle Packaged
cyclones small rates up to pressure
modules 100,000b/d vessels an
can be skid can fit into
mounted. diameter
vessel.
Hydraulically Offshore 15-40 Compact, Less Prone to
Induced gas small successful scaling.
floatation modules with Requires
can be skid suspended blanket ga
mounted. solids avoid oxyg
contamina

Induced Gas Offshore 15-40 10 Compact, Low Opera

Floatation small weight
(IGF) modules requires
can be skid blanket ga
mounted. that
risesattrac
droplet to
avoid oxyg
contamina
Heavy we
Dissolved Onshore 15-40 10 Ideal for
Gas use
Floatation onshore
(DGF)
Membranes Offshore 1-40 0.01 Compact Suitable for Not used m
dissolved in EP due
oil not susceptibi
suspended of membr
fouling.
Media Offshore 1-40 Compact Suitable for Not much
Filtration dissolved since they
oil not suffer
suspended blockage a
create
additional
waste pro
Micro Offshore 2 Not much
Filtration since they
suffer
blockage a
create
additional
waste pro
Mesh Offshore 5 Not much
Coalescer since they
suffer
blockage a
create
additional
waste pro
1. As such, the Proposed Disposal method of the treated water is
 FWKO for 2 phase separation and enhancing solid settling & removal
  Hydrocyclone de-oiler which generally removes 80-90% of oil present and can
achieve outlet concentrations of 15ppm
 Degasser to take off gas
 Flocculator to ease flocculation problems and salinity

Inlet produced water

Gas out
Gas in
FWKO
Solids out Non operational route Settling tank IG
F Water out
Oil to recycle
Suspended solids out

Hydrocyclone On a barge
Gas to flare pot
degasser
Water to degasser
Water to overboard 15ppm
Water outlet
flocculator

2. Specification for the water at the point of disposal

The quantity of produced water from the two trains is 20,983bbl/d.
The specification for the water we are disposing will be 15ppm which is in line with
Shell group minimum environmental standard (MES 2003) Oil in water < 30mg/l in
open sea.
The water at the point of disposal will be free of scale, solids and flocculation problems.
This design will also benefit the use of injecting produced water into hydrocarbon
bearing reservoirs on the longer term. Removal of solids and salinity will prevent
clogging up injection wells as remediation will be very expensive.
Note that Individual hydrocyclone liners typically have a capacity of 1-10 thousand
bpd, and are packaged into one or more pressure vessels to minimise costs. Sufficient
liners for 100,000 bpd capacity would typically fit in a single 42" diameter vessel.

3. A policy for non-operational equipment

After considering all other options, in the instances when the above equipment is non
operational, the produced water will be collected in environmental barges with
settling oily water tank with an IGF by which oil droplets are removed from water by
attachment to rising gas bubbles. The water will then be discharge at 15ppm to the
open sea.
Another means is to evacuate daily produced water from a storage tank installed on
the platform which will transport the produced water to the nearest terminal along the
coastline for treatment and disposal

7.4 EXPORT GAS CUSTOMER SPECIFICATION

 Meeting the sales contract gas dew point involves two aspects:
1) Water dew pointing
2) Hydrocarbon dew pointing
It is feasible to achieve these aspects in combination or separately. The table
below shows alternative techniques for achieving the goals.
Low temperature Heat exchange by cooling the inflow gas
separation (stream 23) with outgoing gas, while
With glycol inhibiting hydrate formation with
injection (LTS) glycol. By passing the outflow gas from
exchanger through Joule-Thompson
valve, the liquid components drop out.
Low temperature Heat exchange by cooling the inflow gas
separation with (stream 23) with outgoing gas. By passing
hydrate melting the outflow gas from exchanger through
(LTX) Joule-Thompson valve, the liquid
components drop out.
Refrigeration Liquids removed by cooling with
propane. Hydrate formation is inhibited
with glycol. It is frequently used for
meeting sales dew point specifications.
Solid desiccant As in LTX, but with reduced cycle time.
adsorption NGL, initially adsorbed by the solid
desiccant and eventually driven out by
water during the long cycle, now remain
adsorbed and can be recovered.
J-T LTS
PLANT
Yes Is the field pressure sufficient
throughout the field life?
LTS PROCESS
Consider LTX if space can be
met.
Advantage: low dew points
reached initially.
Disadvantages: glycol regeneration
required; not always a suitable
long term solution due to
decreasing wellhead pressure.
Advantage: external heating not
required.
Disadvantages: not such low dew
points can be reached without
external heating.
Advantages: reliable; low dew
points achieved; independent of
available pressure.
Disadvantages: expensive
Advantage: heavy hydrocarbons
are also recovered.
Disadvantages: when compared
with LTX, LTS and refrigeration;
hydrocarbon dew point reduction is
small.
No
LTS in early field life, When
pressure declines, supplement
cooling with mechanical
refrigeration or install pre-plant
booster compression. Also
consider silica gel.
127 bar

J-T VALVE Glycol

contacting
envelope
100 bar

50%
75%

25%

0°C
 EXPORT GAS METERING PACKAGE

Z-2300 STEAM TO ATMOSPHERE

Dry lean export
gas out

LC GAS/GAS EXCHANGER

Glycol dehydration
package
FREE WATER
KNOCK-OUT

LC
LEAN GLYCOL
J-T VALVE
V-2810
LEAN GLYCOL PUMP

WATER TO FLASH DRUM LC

LC LOW TEMPERATURE
SEPARATOR
NGL HC TO STABILIZATION
RICH GLYCOL
7.5 EVALUATION FOR C3+ SALES

The option of sending the gas to an existing deep recovery NGL extraction plant
employing turbo expander process is very beneficial as detailed below:

NGL components in gas stream is C3+

% composition of NGL in Gas export line is given below:
Component Stream 23
C3 0.1161
C4 0.0366
C5 0.0074
C6 0.0007
C7 0.0001
Total 0.1609

% of NGL (C3+) in export line is 16.09%

 Flow rate = 600 kmol/hr
 Calorific value = 48 MJ/kg
 Density = 570 kg/m3
 MW = 50 kg/kmol
NGL sales price = $150/tonne
NGL processing = $ 50/tonne
Gas price = $1.90/GJ

Molar flow rate of NGL (C3+) in export gas stream = 0.1609 * 600 = 96.54 kmol/hr

Mass flow rate of NGL (C3+) = 96.54 * 50 = 4827 kg/hr

Annual mass flow rate of NGL = 4827 * 24 * 365

= 42284520 kg/year
= 42284.520 tonnes/year

Sales price on NGL in One year = 42284.52 * 150 = $6,342,678

Cost of processing NGL in One year = 42284.52 * 50 = $2,114,226

Annual profit on NGL = $6,342,678 - $2,114,226 = $4,228,452:00

By selling gas to the power plant;

Calorific value = 48 MJ/kg

Gas price = $1.90
Mass of gas per year = 42284520 kg
Annual Revenue from selling as gas = 0.048 * 42284520 * 1.90 = $3,856,348:22

From the above calculations, it is seen that by extracting NGL from the gas and
selling, we make $372,103.78 per annum more than selling gas directly to the power
station.
It is important to note that sales to the power station could still be available from the
light end gas from the refinery.
Given:
The glycol system manufacturer’s design are:
 Lean TEG Concentration 98.0%
 Glycol Circulation rate: 0.5m3/h
 Height of packing in contractor: 2.5m (about 1.5 theoretical
stages)
The required state is to have a review of the glycol system design. To meet
specification, the amount of water in the gas is to be determined.

For a colder climate as Caspian sea, the assumption is that export gas temperature
should be between 0 and -10°C. The water dew point is assumed - 5°C at 13MPa.

Glycol contactor temperature = 28C

Glycol contactor pressure = 12.7MPa
From the Equilibrium H20 dewpoint vs temperature at various TEG concentration
graph, the equilibrium dew point is -10°C at a TEG concentration of 97.0%

From the water content of Natural gas graph,

At -5°C, the water content of gas is 53kg/106stdm3
At 28°C, the water content of gas is 420 kg/106stdm3
The water content therefore is 367 kg/106stdm3

TEG recirculation rate

The total gas flowrate is 899mol/hr = 899mol/hr * 23.64 std m3/mol
= 21,252.36 std m3/hr
Glycol recirculation rate =
= Water content * Total gas flowrate sm3/hr * 30ltrTEG/KgH20 * L/1000m3
= 367 * 21,252.36 * 30 * 0.001 * 10-6
= 0.234 m3/hr

Lean TEG concentration required is 97.0%

Glycol recirculation rate = 0.234 m3/hr