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Petroleum Plant Design


December 06, 2014

o Fuel Gas System

The primary source of fuel gas will be downstream of the expander
compressor. For start-up purposes fuel gas will be taken from the two
feed gas lines upstream of plant isolating valves and will tie-in to the
main fuel-gas header upstream of the FG scrubber.
An oriGce type meter shall be installed to measure overall plant gas
consumption, which covers but is not necessary limited to, the
• Fuel gas for gas turbine driven compressors and gas engine
• Fuel gas for hot oil furnace heater
• Purge gas
• Pilot gas for Kare and burn-pit ignition system
The Fuel Gas Package will comprise of the following:
• Fuel Gas Scrubber (1 x 100 %)
• Fuel Gas Filters (2 x 100 %)
• Fuel Gas Heater (1 x 100 %)
The fuel gas off take is at 285 psig before let down into the fuel gas
scrubber. The gas is totally dry for star-up, the gas taken from the
pipelines will be water-saturated, so a fuel-gas heater is provided to
elevate the gas temperatures.

o Seal Gas System

The system will be designed and supplied by the selected
Compressor VENDOR.
The seal gas system shall be able to handle the primary seal gas
requirement of the selected gas compressors.
The Seal Gas Package might comprise of the following:
• Seal Gas Scrubber (1 x 100 %)
• Seal Gas Filter/Coalesces (2 x 100% )
• Seal Gas Electrical Heaters (2 x 100%)
In addition, seal gas treatment and its control system shall be
provided on the compressor skids.

o Flare and Vent Systems

All hydrocarbon pressure relieving devices, with the exception of low
temperature extraction section gases, will discharge to the high
pressure Kare header. This includes PSVs, rupture disks if approved
for use, and emergency blowdown valves. To prevent any liquid
entering the Kare stack, a Kare K.O. drum, and liquid removal pumps
will be required. Downstream of the KO drum a water seal-drum shall
be provided to prevent air from entering the Kare header system.
The Flare Capacity shall be based on a worst-case scenario. The
design shall be completed in detail engineering.
A Kare header designed for the maximum plant throughput will pass
250 MMscfd under blocked outlet condition. The emergency
blowdown rate will quickly reduce to below the normal maximum
throughput of 250 MMscfd and is not the controlling case. If
adequate protection against blocked discharge and failure of the
protective systems cannot be economically achieved relative to the
cost of a larger capacity Kare system the system shall be sized for
the maximum throughput. It is anticipated that an elevated Kare
system will be used.
In order to reduce the header size a maximum Mach number of 0.7
may be used for emergency discharge assuming the use of a
conventional pipe Kare. Consideration is also to be given to the use of
a sonic Kare tip operating at an elevated back pressure
(approximately 30-50 psig at the tip inlet) which will considerably
reduce radiation levels at and around the plant.
In addition to the HP Kare a cold vent line shall be installed, which will
be elevated and suspended from the HP Kare stack. Some of the
relief valve discharges and vents in the unit are at a very cold
temperature and cannot be sent to the wet carbon steel Kare system.
These cold discharges would cause the formation of ice and hydrates
with potential blockage of the free path to the Kare. The cold
temperature of these discharges are also too cold for the use of
carbon steel material in the piping and Kare. Therefore a separate
cold Kare system consisting of a stainless steel, (or other material
suitable for the discharge condition), Kare header shall be provided.
Simulation indicates that cold liquid will not condense out during
discharge, so a KO drum has not been indicated for the cold vent
system. Bidders to conGrm this fact or advise the installation of a SS
KO-drum. Use of this separate line for the relatively low pressure De-
C2 discharge allows a higher back pressure in the CS HP Kare header
thus reducing header size.
The radiation levels for personnel and equipment at the limit of the
restriction zone resulting from the HP Flare shall not be more than the
(ref: API 520 Part II - Sizing, Selection and Installation of Pressure-
Relieving Devices in ReGneries):
• Equipment Protection 5000 Btu / (hr.ft2)
• Personnel, one minute exposure 1500 Btu / (hr.ft2)
• Personnel, continuous exposure 500 Btu / (hr.ft2)
Liquids collecting in the Flare K.O. Drum are to be directed via the
Flare K.O. pump to the Closed Drain Drum. The requirement for sizing
of these pumps is removal of all liquid between LLH and LLL in 30
The water seal drum will have a permanent water-line connection,
level controlled to maintain a position seal in the drum. A water seal
drum is not envisaged for the cold vent. This cold vent line will be
fuel-gas purged only from its extreme upstream point.
The Kare system will comprise of:
• HP Kare header
• HP Kare stack
• Cold vent header
• HP Kare tip
• Flare ignition system
• HP Kare KO drum
• HP Kare KO drum pump
• HP water seal drum
Individual atmospheric vents are to be used where possible with
crossovers minimized and air-cooled exchanger fans used to assist
dispersion. Flame arrestors shall be Gtted at individual local
atmospheric vents.
o Instrument and Utility Air System
The Instrument and Utility Air System will comprise the following
main components:
• Instrument / Utility Air Compressors (2 x 100 %)
• Instrument Air Drier (2 x 100 %)
• Instrument / Air Receiver
• Utility Air Receiver
• Instrument and Utility Air Distribution Systems
Air Compressors and Air Dryers capacity is shown in Table-4.
The air receiver shall be sized for 30 minutes of air capacity from low
pressure alarm down to low low pressure shutdown initiation.

o Diesel Fuel System

The diesel storage facility with Glter coalesces; loading facilities and
transfer are to be provided. The storage tank shall be designed to
accommodate the diesel fuel demand of diesel generator for 8 days
in base load continuous operation condition, supply the diesel Gre
pumps and provide fuel for vehicle use through a day tank and vehicle
Gll hose.
The Diesel Fuel system comprises of:
• Diesel Fuel Storage Tank
• Diesel Fuel Daily Tank with Gll hose
• Diesel Fuel Loading Pump
• Diesel Fuel Transfer Pump
• Diesel Fuel Transfer Filter
Oil and Gas Process

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