EPCIC FOR ERIEMU WELL 11T SURFACE FACILITIES

UPGRADE PROJECT IN OML 30

PROJECT TITLE

EPCIC FOR ERIEMU WELL 11T SURFACE FACILITIES UPGRADE IN OML 30

DOCUMENT TITLE

PROCESS SIMULATION REPORT

DOCUMENT NUMBER

OML30-ERU-PRS-DOC-00002-00

F02 20-06-19 Approved for Construction MS OA ME MA

F01 29-03-17 Approved for Construction MS OA ME MA
A01 06-02-17 Issued for Review MS OA ME MA
REV DATE PURPOSE PREPARED CHECKED QA/QC APPROVED
Document No: OML30-ERU-PRS-DOC-00002-00
MAVI-ENERGY AND PAVILLION
HEAD OFFICE
No. 2 DORE ROLAND STREET
KM 20 NPA EXPRESSWAY, UGBUWANGUE
WARRI, DELTA STATE

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Abbreviations
API American Petroleum Institute
ANSI America National Standard Institute
ASME American Society of Mechanical Engineer
BDEP Basic Design and Engineering Package
BDV Blowdown Valve
BFD Basis for Design
BOPD Barrel of Oil per day
CFD Computational Fluid Dynamics
CGR Condensate to Gas Ratio
CITHP Closed-in Tubing Head Pressure
Client NPDC/SNRL
DED Detailed Engineering Design
E&I Electrical & Instrumentation
EPCIC Engineer, Procure, Construct, Install, & Commission
EPCIC Contractor Mavi Energy Dev. Company Ltd/Pavillion Petroleum Ltd
Consortium
ESD Emergency Shut-Down
ESDV Emergency Shut-Down Valve
HIPS High Integrity Protective System
HTRI Heat Transfer Research Institute
FCV Flow Control Valve
FEED Front End Engineering and Design
FS Flowstation
HAZID Hazard Identification
HAZOP Hazard and Operability
HC Hydrocarbon
HEOSL Heritage Energy Operational Services Ltd
HP High Pressure
IPF Instrumented Protective Function
IPS Instrumented Protective System
LP Low Pressure
LTI Lost Time Injury
Mbopd ‘000 barrels of oil per day
MEDCL Mavi Energy Development Company Ltd
MMSCFD Million Standard Cubic Feet per Day
NPDC Nigerian Petroleum Development Company Ltd
OSD Operational Shutdown

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PAVPL Pavillion Petroleum Ltd

PFS Process Flow Scheme
P&ID Process & Instrumentation Diagram
SFR Safe Failure Robustness
SIL Safety Integrity Level
SIS Safety Instrumented System
SNRL Shoreline Natural Resources Ltd
UEFS Utility Engineering Flow Scheme
UFS Utility Flow Scheme
WGR Water/Gas Ratio
XHP Extra High Pressure

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Table of Contents
Abbreviations………………………………………………………………………………………………………………………………………………………………………………………2
1.0 INTRODUCTION ................................................................................................................................................................................ 6

1.1 PROJECT BACKGROUND........................................................................................................................ 6

1.2 PURPOSE OF DOCUMENT ..................................................................................................................... 6
1.3 DEFINITIONS ........................................................................................................................................ 6
1.4 SYSTEM OF UNITS ............................................................................................................................... 7
2.0 SCOPE OF WORK AND BATTERY LIMIT ............................................................................................................................................... 9

2.1 SCOPE OF W ORK................................................................................................................................. 9

2.2 BATTERY LIMIT .................................................................................................................................... 9
3.0 CODES AND STANDARDS................................................................................................................................................................. 10

3.1 GENERAL .......................................................................................................................................... 10

3.2 ORDER OF PRIORITY .......................................................................................................................... 10
3.3 LEGISLATION AND REGULATIONS ........................................................................................................ 10
3.4 PROJECT DOCUMENTS....................................................................................................................... 11
3.5 INTERNATIONAL STANDARDS .............................................................................................................. 11
3.6 SUPPLEMENTARY CODES ................................................................................................................... 11
4.0 ENVIRONMENTAL DATA.................................................................................................................................................................. 12

4.1 TERRAIN ........................................................................................................................................... 12

4.2 TEMPERATURES ................................................................................................................................ 12
4.3 RAINFALL .......................................................................................................................................... 12
4.4 W IND SPEED ..................................................................................................................................... 12
4.5 ENTOMOLOGY AND VERMIN ................................................................................................................ 12
4.6 LIGHTNING ........................................................................................................................................ 12
4.7 SITE ALTITUDE ................................................................................................................................... 12
4.8 FUNGI AND GROWTHS ........................................................................................................................ 12
4.9 DUST ................................................................................................................................................ 12
5.0 PROCESS SIMULATION ANALYSIS ............................................................................................................................................. 13

5.1 PURPOSE ........................................................................................................................................ 13

5.2 SUMMARY OF RESULTS ...................................................................................................................... 13
6.0 SIMULATION BASIS.................................................................................................................................................................... 14

6.1 SIMULATION SOFTWARE........................................................................................................................ 14

6.2 THERMODYNAMIC BASIS ...................................................................................................................... 14
6.3 FEED STREAM COMPOSITION ................................................................................................................ 14
6.4 FLOW RATE ........................................................................................................................................ 15
6.5 TEMPERATURE AND PRESSURE................................................................................................................ 15
6.6 FLOWLINE PARAMETERS ....................................................................................................................... 15
6.6.1 Flowline Materials ....................................................................................................................................... 15
6.6.2 Flowline diameter and Length ........................................................................................................... 15
6.7 FLOWLINE GEOMETRY ....................................................................................................................... 16
6.8 PIPE W ALL ROUGHNESS .................................................................................................................... 17
6.9 FLOWLINE BURIAL DEPTHS................................................................................................................. 17
6.10 AMBIENT TEMPERATURES ................................................................................................................ 17
6.11 THERMAL CONDUCTIVITIES .............................................................................................................. 17
7.0 SIMULATION METHODOLOGY ................................................................................................................................................... 19

7.1 ERIEMU WELL 11T AND FACILITY............................................................................................................ 19

7.2 RESERVOIR CONDITIONS ...................................................................................................................... 22
7.3 SIZING CRITERIA .................................................................................................................................. 22

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7.4 SENSITIVITY CASES. .............................................................................................................................. 22

7.5 CASE DESCRIPTION ............................................................................................................................. 22
8.0 RESULT .......................................................................................................................................................................................... 24

8.1 PHASE ENVELOPE ................................................................................................................................ 24

8.2 HYDRATE ANALYSIS ............................................................................................................................. 24
8.3 FLOWLINE SIZING................................................................................................................................. 25
8.4 HEAT EXCHANGER (E-100) AND (H-1810) SIZING ................................................................................. 26
8.5 XHP SEPARATOR (V-105) ................................................................................................................... 27
8.6 LOW TEMPERATURE STUDIES .................................................................................................................. 27
8.6.1 START-UP ........................................................................................................................................ 27
8.6.2 DEPRESSURIZATION / BLOWDOWN...................................................................................................... 27
9.0 CONCLUSION AND RECOMMENDATIONS .............................................................................................................................. 30

10.0 REFERENCE ................................................................................................................................................................................ 31

APPENDIX: Process Simulation Flow Diagram (PFD) ................................................................................................................... 32

APPENDIX I: ERIEMU WELL 11T SIMULATION .................................................................................................. 33

APPENDIX II: ERIEMU WELL 11T FLOWLINE AND FACILITIES SIMULATION FOR (CASE 1) ....................................... 34
APPENDIX III: ERIEMU WELL 11T FLOWLINE AND FACILITIES SIMULATION FOR (CASE 2)....................................... 35

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1.0 INTRODUCTION
1.1 Project Background

Eriemu Well 11T, previously an oil well, was re-completed in 2010 as a gas well
to provide lift gas for other oil wells in Eriemu field, but has remained shut in
due to high pressures recorded for the well at re-completion. The Closed-in
Tubing Head Pressure (CITHP) of the well is 2844.2 Psig, a pressure much higher
than the capacity of existing flowline, and inlet facilities in Eriemu flowstation.
This project is aimed at safe evacuation of the Eriemu well 11T fluid in line with
NPDC specification and process control/safeguarding principles as well as,
protecting the downstream surface facilities.
The project includes but not limited to Engineering, Procurement,
Construction/ Installation, Testing and Commissioning of the following:
- A new 4’’ x 800m Carbon Steel API 5L X52, Sch. xxs flowline.
- One (1) no. Water Bath Heater.
- One (1) no. Shell and Tube Heat Exchanger
- A Corrosion inhibition package.
- Pressure Control Valve at the Eriemu XHP Separator inlet.
- Various pneumatic field instruments, to enable safe production of the
well.
- Associated Civil, Instrumentation, and Electrical installations for
effective functioning, and integration of the new facilities with existing
Eriemu F/S facilities.
- Integration of the new equipment with existing Eriemu F/S facilities.

1.2 Purpose of Document

The purpose of this document is to provide detail information on process
simulation and design for over-pressure protection of the new Eriemu well 11T
flowline and the existing downstream surface facilities.
This is to safely evacuate the Eriemu well11Tfluid to Eriemu flow station for use
in gas lifting of other (oil) wells in Eriemu field, which is the main objective of the
Eriemu well11T surface facility over-pressure protection project.

1.3 Definitions
The words following are used in the contexts defined against them, in this
document:

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Principal or Client The party who initiates the project and

ultimately pays for its design and construction,
which in this case, is (NPDC/Shoreline Natural
Resources).
EPCIC Mavi-Pavillion The party that carries out all or part of the
design, engineering, procurement,
construction, commissioning or management of
the project facilities, which in this case, is the
Mavi Energy Development Company
Ltd/Pavillion Petroleum Ltd Consortium.
Manufacturer or Vendor The party that manufactures and supplies
equipment and services to perform the duties
specified by the Mavi-Pavillion.
Engineer The discipline engineer responsible to the EPCIC
Mavi-Pavillion for assurance that the
engineering design of the works complies with
the requirements of relevant Codes and
Standards, and any additional requirements
established by the Client.
Party Means the Client (NPDC/Shoreline), the EPCIC
Mavi-Pavillion, or Manufacturer/Vendor, as the
context requires.
Shall Indicates that a provision is mandatory
requirement.
Should Indicates that a provision is a preferred, or
recommended course of action.
May Indicates that a provision is an acceptable
course of action.

1.4 System of Units

The units shown below (SI units in general) shall be used as the main design
units and all values quoted shall be in these units. Alternative values and units
will be indicated in brackets after the design unit, when it is believed
desirable. The size of the unit shall be appropriate to the value being
measured i.e. mm - m – km.

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Units of Measurements

Description Unit

Nominal pipe diameters Mm

wall Thickness Mm

Valve Sizes mm (or inch)

Length m (mm or km)

Area m²

Liquid Volume m³

Volumetric Oil Flow MBPD

Rate
Any volumetric other m³/h
Flow Rate
Standard Gas MMSCFD
Volumetric Flow Rate
Velocity m/s

Density kg/m³

Pressure bara or barg

Temperature C

Viscosity cP

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2.0 SCOPE OF WORK AND BATTERY LIMIT

2.1 Scope of Work
The project scope comprises: Engineering, Procurement, Construction/
Installation, Testing and Commissioning of the following:
- A new 4’’ x 800m, Carbon Steel API 5L X52, Sch. xxs flowline
- One (1) no. Water Bath Heater
- One (1) no. Shell and Tube Heat Exchanger
- A Corrosion inhibition package
- Flow Control Valve downstream Shell and Tube Heat Exchanger
- Flow Control Valve at the Eriemu XHP Separator inlet;
- Various pneumatic field instruments, to enable safe production of the
well.
- Associated Civil, Instrumentation, and Electrical installations for
effective functioning, and integration of the new facilities with existing
Eriemu F/S facilities;
- Integration of the new equipment with existing Eriemu F/S facilities

2.2 Battery Limit

The battery limits for process simulation work for the Eriemu well 11Tsurface
facilities upgrade in OML 30 are:
- Eriemu Well 11T wellhead hook-up flange
- Eriemu Flow station XHP Separator outlet.

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3.0 CODES AND STANDARDS

3.1 General
The current editions of all codes and standards as at the date of this document, shall apply.
Deviations from applicable rules, codes and standards shall be subject to written consent
from the NPDC/SNRL. The design of the pipelines should comply with the prevailing National
Standards and Regulations applicable in Nigeria.

3.2 Order of Priority

- Nigerian Statutory Standards and Regulations
- NPDC specifications and standards
- Project documents
- Industry standards
- Vendor / contractor codes and working standards

3.3 Legislation and Regulations

Regulations Competent Authority

Oil and Gas Pipeline Legislation of 1995 DPR (Department of

Petroleum
Resources)
Environmental Guidelines and Standards DPR, NNPC, FEPA,
for the Petroleum Industry in Nigeria State
(EGASPIN), DPR, July 2002 Revision Authorities.

Federal Environmental Protection Agency FEPA, State EPAS.

Act, 1988. Cap.131, Vol: IX P. 6303

Petroleum Act, 1969. Cap 350, Vol XIX, P. Minister of Petroleum

12644 Resources DPR, FEPA
Petroleum Regulation, 1964, Article 45 DPR, FEPA, State
EPAS.

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3.4 Project Documents

S/N Document Number Document Description
OML30-ERU-PRS-DOC- Heat and Material
1
00001-00 Balance
OML30-ERU-PRS-DOC-
2 Process Simulation Report
00002-00

OML30-ERU-PRS-DOC-
3 Utility Report
00009-00

OML30-ERU-PPL-DOC-
4 Pipeline Design Report
00004-00

3.5 International Standards

The primary codes guiding this Process Design Philosophy are:
API 521: Pressure-relieving and De-pressuring Systems)

3.6 Supplementary Codes

American Petroleum Institute
API 6D: Pipeline Valves
International Standard Organisation
ISO 9001: Quality Systems – Model for Quality Assurance in Design, Development, Production,
Installation and Servicing.
American Society of Mechanical Engineers
ASME B31.8: Gas Transmission and Distribution Piping

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4.0 ENVIRONMENTAL DATA

The environmental data given below is typical of the conditions prevalent in
the Land region and forms the environmental basis of the engineering design.

4.1 Terrain
The Eriemu facility is situated on a relatively even surface land area with a
good drainage system but with seasonal swamp occurrences

4.2 Temperatures
- Mean minimum temperature: 23 oC (73oF)
- Minimum temperature: 18oC (65oF)
- Mean maximum temperature: 31oC (88oF)
- Peak temperature: 41oC (106oF)
- Humidity: 100%

4.3 Rainfall
Heavy rainfall can be expected in the wet season during the months of April
through October.
- Average annual rainfall: 3800mm (150-inch)
- Mean maximum hourly rainfall: 100mm (4-inch)

4.4 Wind Speed

- Design Wind Speed for structural design: 40 m/s
- Wind Speed (Max): 60km/hr

4.5 Entomology and vermin

As prevalent in the Niger Delta with thick forest and swamp habitats.

4.6 Lightning
Lightning is frequent in the rainy season.

4.7 Site altitude

Slightly above sea level.

4.8 Fungi and Growths

As prevalent in the Niger Delta with thick forest and swamp habitats.

4.9 Dust
During November-December of every year, which is the harmattan season,
the atmosphere is laden with extremely fine dust (particle size of 5 microns or
less), which can penetrate equipment, block air filters etc.

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5.0 PROCESS SIMULATION ANALYSIS

5.1 Purpose
This report presents the process simulation of Eriemu Well 11T Surface Facility
over-pressure Protection Project. The analysis comprises of the following:
- Phase Envelope
- Steady State Hydraulic Analysis – to determine flowing conditions
(pressure, temperature & phase velocities) and confirms the flowline
size.
- Hydrate Risk Assessment
- Low Temperature Studies – To determine Lowest Design Temperature
(LDT) during Depressurization and Startup.

5.2 Summary of Results

Without heating up the Eriemu 11T Well Fluid, hydrate will form downstream
the (100-FCV-105) due to Joule Thompson effect. A two-stage heating is
introduced to heat up the Eriemu Well 11T fluid in the shell and tube heat
exchanger (E-100) and water bath heater (H-1810),which is sufficient to keep
(100-FCV-105) downstream fluid temperature above the hydrate formation
temperature of 14.07oC. Water in the water bath heater (H-1810) shall be
heated in the burner to supply Hot Water at a temperature of 90oC to heat
the Eriemu Well 11T fluid in the water bath heater (H-1810).

Based on the flowline depressurization results, the minimum temperature that

will be experienced within the flowline is 17.69oC. The Lowest Design
Temperature (LDT) calculated for the piping downstream the (100-HCV-002)
after blowdown is -66.8oC. Hence, austenitic stainless steel is the material
recommended for piping downstream the (100-HCV-002).

The Lowest Design Temperature (LDT) calculated for the piping between
(100-UZV-111) and (100-XZV-107) after depressurization is 18.9oC. The minimum
temperature of piping downstream the (100-HCV-001) after blowdown is -
75oC. Hence, austenitic stainless steel is the material recommended for piping
downstream the (100-HCV-001).

During black start-up considering several scenarios like back pressurization to

0 barg and 10 barg, cryogenic condition will exist in the piping downstream
the 100-FCV-106 and 100-FCV-105 for all cases. For flowline parameters,
please refer to the Pipeline Design Report (document OML30-ERU-PPL-DOC-
00001-01_C01) for details of the flowline selection and sizing.

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6.0 SIMULATION BASIS

6.1 Simulation Software
The simulation software used for the process modeling is Aspen HYSYS V10.0.

6.2 Thermodynamic Basis

The thermodynamics basis used for the base cases is the Peng Robinson (PR)
Equation of State. Beggs and Brill flow (1979) correlation was used for pressure
drop calculations along the flowline.

6.3 Feed Stream Composition

The reservoir composition and properties in Table 1 is provided by HEOSL in
the condensate study report [Heritage Energy Eriemu-11T Recomb-final rep]
(Ref.: 6) was used as input during the simulation. Normal boiling point (NBP)
was not given in the report hence a value for an identical reservoir was used.
The well fluid has a CGR of 3.5 bbl/MMSCF and BS&W of 8% at flowing
condition as stated.
The composition were given on dry basis and the corresponding composition
on wet basis were determined with Hysys Saturate utility

Table 1: Well 11T Compositions at Flowing conditions on dry and wet basis

Composition At Flowing At Flowing

Condition @ Condition @
dry basis wet basis
Mole Fraction Mole Fraction
Nitrogen 0.0031 0.0031
CO2 0.0062 0.0062
0.0031
0.0062
H2S 0.0000 0.0000
0.9471
Methane 0.9471 0.9467
0.0367
Ethane 0.0367 0.0367
0.0007
Propane 0.0007 0.0007
0.0006
i-Butane 0.0006 0.0006
0.0000
n-Butane 0.0000 0.0000
0.0001
i-Pentane 0.0001 0.0001
0.0001
n-Pentane 0.0001 0.0001
0.0005
n-Hexane 0.0005 0.0005
0.0000
H2O 0.0000 0.0005
0.0049
1.00000

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C7+ 0.0049 0.0049

TOTAL 1.00000 1.00000

Table 2: Eriemu Well 11T C7+ Properties

NBP Liquid Density
Name Mw
(°C) (Kg/M3)
C7+ 78.18 126 786.5

6.4 Flow Rate

The flowrates used in the design are shown in Table 3 below:
Table 3: Design Flow rate & Boundaries

Design Flowrate
Item
(MMSCF/D)
Flowline 26
XHP Separator 13

The design flow for the XHP Separator is 13MMSCFD, a minimum flow of
4.3MMSCFD was considered for the simulation report.

6.5 Temperature and Pressure

The well Fluid conditions are as stated below: (Ref: 1)
Table 4: Well Conditions

Wells Reservoir Reservoir Max FTHT Max CITHP

Pressure Temperature (oC) FTHP (barg)
(barg) (oC) (barg)

Eriemu
243.3 63.89 29.83 195 196
Well 11T

6.6 Flowline Parameters

6.6.1 Flowline Materials
Eriemu Well 11T Flowline material shall be carbon steel. (Ref… 1)

6.6.2 Flowline diameter and Length

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Table 5: Pipeline Design Data

Inner Wall
Design Outer
Diamet Thickness Length
Pipeline pressure Diamet
er WT incl. (km)
(barg) er (mm)
(mm) CA (mm)
Well 11T Please refer to the Pipeline Design Report
to(100U (document OML30-ERU-PPL-DOC-00004-00) for
ZV-111) details of the flowline selection and sizing.

6.7 Flowline Geometry

The flowline geometry are given below

Table 6: Flowline Geometry

Distance (m) Elevation (m)

1 0.00 0.00
2 10.00 0.00
3 10.00 0.00
4 28.00 0.00
5 28.00 0.00
6 55.00 0.00
7 55.00 0.00
8 56.47 0.00
9 56.47 0.00
10 87.47 0.00
11 87.47 0.00
12 162.47 0.00
13 162.47 0.00
14 270.47 0.00
15 270.47 0.00
16 738.47 0.00
17 738.47 0.00
18 810.47 0.00
19 810.47 0.00
20 840.47 0.00
21 840.47 0.00
22 847.47 0.00
23 847.47 0.00
24 848.94 0.00
25 848.94 0.00
26 851.34 0.00

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Table 7: Pipe Fittings

Pipe fittings Quantity Equivalent Length

due to fittings (m)
1 900 Long Elbow 12 24.384

The total flowline length is 875.68m which is due to the total straight pipe
length and the equivalent length due to fittings.

6.8 Pipe Wall Roughness

The following standard pipe wall roughness was used:

Table 8: Pipe Wall Roughness for Eriemu well 11T

Pipeline
Fluid Roughness (mm)
Material

Well 11Twell fluid Carbon Steel 0.05 [ref 1]

6.9 Flowline Burial Depths

The flowline is considered to be in contact with Wet Sand and with a burial
depth of 1.5m below the ground. (Ref… 1).

6.10 Ambient Temperatures

The Ambient Temperatures provided in Ref 1 are as follows:

Table 9: Ambient Temperatures

Temperature Value

Peak Temperature 41°C

Mean Maximum 31°C

Temperature
Minimum Temperature 18°C

Mean Minimum Temperature 23°C

6.11 Thermal Conductivities

The following thermal conductivities thus apply based on (Ref.: 1)

Table 10: Thermal Conductivities

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Material Thermal conductivity (W/m.K)

Carbon Steel 45
Wet Sand 2.1

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7.0 SIMULATION METHODOLOGY

7.1 Eriemu Well 11t and Facility
Well 11T flowing conditions were modelled in a sub-flowsheet. The stream,
“Eriemu Flowing Condition @ dry basis”, represents the composition of
reservoir fluid without water component. This stream is saturated with water at
flowing tubing conditions with Hysys saturate utility to get the stream “Eriemu
Flowing Condition @ wet basis” which is saturated gas. See Appendix I for a
representative HYSYS model for Well 11T model.
To match the properties of Eriemu gas stream with a CGR of
3.5 bbl. /MMSCFD and BW&S of 8%, a three-phase separator was used in the
simulation to split the phases in to gas, condensate and water.
The condensate and water streams were tweaked to meet the conditions
above. This was confirmed by rechecking the calculation in spreadsheet
object (CGR and BS&W matching). The two matched streams, namely;
condensate (Produced Cond.) and water (Produced Water) streams were
then recombined with the produced gas stream using a mixer (Mix-102). The
final stream was then a true representation of Eriemu Well 11T stream.
Downstream Well-11T stream is the wing valve (10-XZV-113). The flow
downstream the wing valve is split in two using (TEE-100) with stream 1
representing the flow line inlet while a dummy stream “OFFSET” is used to fix
the Well 11T production rate entering the flowline.
Eriemu Well 11T flowline is modelled with a single pipe segment. Streams 1
and 2 represent the inlet and outlet. A two stage heating of Eriemu well fluid
was introduced, firstly with the shell and tube Heat exchanger (E-100) and
then water bath heater (H-1810).
The heating up of the fluid act as mitigation against hydrate formation.
Eriemu fluid flow the flowline enters the tubeside of the heat exchanger (E-
100) at 26.03oC and was heated up to 44oC before being choked down to
131barg and 30.9oC with 100-FCV-106.The fluid is then sent to water bath
heater to heat it up to 50oC.
The heating medium for the well fluid is hot water produced from the Water
Bath heater (H-1810) and re-circulated in a closed loop by Hot Water
Recirculation pump (P-1810A/B). After the exchange of heat at shell and
tube exchanger, the hot water in the shell side of E-100 is cooled which is
subsequently heated up in the firetube (burner) of the water bath heater.
The hot water from the firetube is controlled by TCV-001 to regulate the water
temperature to 90oC.

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100-FCV-105 was used to choked down the well fluid from 130 barg to 72
barg and 31.84oC which is the operating pressure of XHP separator (V-105)

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 EPCIC FOR ERIEMU WELL 11T SURFACE FACILITIES
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TO GASLIFT MANIFOLD

(100-HCV-002) (100-HCV-001)
TO AFIESERE COMP.
STATION
P
I

FLOWLINE (E-100) XHP-

SEPARATOR

(100-XZV-113) (100-UZV-111) (100-FCV-106) (100-FCV-105)

(H-1810) (100-XZV-107)

WELL-11T
GAS
WELLHEAD

(105-UZV-002) (105-LCV-001)

(P-1810A/B)

FIGURE 1: Process Schematic for Eriemu Well-11T Surface Facilities Upgrade Project
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7.2 Reservoir Conditions

The composition given (Ref 6) was at dry basis and was saturated to form the
Feed Stream composition tagged “Eriemu Flowing Condition @ wet basis”.
The simulation FTHP and FTHT was assumed to be the operating pressure and
temperature upstream of the flowline.

7.3 Sizing Criteria

The flow line was sized based on the following criteria:
 Normal operating flowline fluid velocity shall be less than 18.3 m/s (60 ft.
/s). (Ref.:1)
 Erosional velocity ratio in the flowline shall be less than one (1) in all
cases- (API RP-14E)

7.4 Sensitivity Cases.

The following factors were used to generate the boundary in which the
simulation cases were defined.
- Wet Season at an ambient temperature of 23 oC
- Dry Season at an ambient temperature of 38 oC
- Minimum Low ambient temperature of 18 oC
- Production Rate of Well-11T (@ 26 and 4.3 MMSCFD)

7.5 Case Description

The following 6 (Six) cases were investigated to generate the boundary,
including sensitivities in which the facilities and pipeline were designed.
Case 1A
Pipeline will be considered as being in contact with Wet Sand throughout the
pipeline length at an ambient temperature of 23 oC and at design flow rate
of 26 MMSCFD.
Case 1B
Pipeline will be considered as being in contact with swamp water and wet
sand throughout the pipeline length at an ambient temperature of 18 oC and
at design flow rate of 26 MMSCFD.
Case 1C
The dry season scenario will be modelled as pipeline in contact with wet sand
throughout its length at an ambient temperature of 31 oC and at design flow
rate of 26 MMSCFD.

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CASE 2A
Pipeline will be considered as being in contact with Wet Sand throughout the
pipeline length at an ambient temperature of 23oC and at normal operating
flow rate of 4.3 MMSCFD.
Case 2B
Pipeline will be considered as being in contact with swamp water and wet
sand throughout the pipeline length at an ambient temperature of 18 oC and
at normal operating flow rate of 4.3 MMSCFD.
Case 2C
The dry season scenario will be modeled as pipeline in contact with wet sand
throughout its length at an ambient temperature of 31oC and at normal
operating flow rate of 4.3 MMSCFD.

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8.0 RESULT
For stream properties, please refer to Heat and Material Balance report
(OML30-ERU-PRS-DOC-00001-00)

8.1 Phase Envelope

The hydrocarbon phase envelope of Eriemu Well-11T fluid shows that it is a
single-phase fluid (only gas phase).

Figure 2: Eriemu Well 11T Fluid Phase Envelope

8.2 Hydrate Analysis

Hydrate analysis of the flowline were performed. The arrival temperature of
the well fluid to E-100 is 26.03oC which is higher than the hydrate formation
temperature of 21.85oC at this pipe segment, hence hydrate will not be
experienced in the flowline. Analysis was also carried out piping downstream
100-FCV-106 (stream 4) and 100-FCV-105 (stream 12).
Without heating up Eriemu fluid at the shell and tube exchanger (E-100), the
temperature resulting of stream 4 is 12.39oC which is below the Hydrate
formation temperature of 18.9oC. Likewise without heating up at the water
bath heater (H-1810), the temperature resulting of stream 12 is 10.1oC which is
below the Hydrate formation temperature of 14.1oC
This means that the piping downstream the 100-FCV-106 and 100-FCV-105 are
at risk of hydrate formation if Well-11T fluid is not heated up to move away
from the hydrate zone after pressure letdown across the valves.
Heating up the well fluid in E-100 and H-1810 to a temperature of
approximately 44oC and 50oC are sufficient to maintain the fluid above is

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hydrate formation zone and also reduce the operational and economic
effects of operating these heaters at higher duty should these temperature
i.e (44oC and 50oC) are increased further.

Table 11: Hydrate Formation Temperature downstream of 100-FCV-106

Table 12: Hydrate Formation Temperature downstream of 100-FCV-105

8.3 Flowline Sizing

The Eriemu Well-11T Flowline was sized based on the criteria set in section 4.3.
(i.e. API RP-14E). Cases 1A, 1B and 1C were considered during the flowline
sizing.
In all the cases, the use of 4” (ID = 79.44mm) Flowline resulted in a maximum
fluid velocity and erosional velocity of 7.7 m/s and 9.5 m/s respectively. See
Figure-3 below. Using API RP 14E method for continuous service, the maximum
erosional velocity ratio (EVR) calculated for all the three scenarios (cases) is
0.82 m/s. This well within the API RP 14E limit of 18.3 m/s, hence the 4’’
(ID=79.44mm) XXS SCH flowline is adequate to carry the flow.
During normal operating conditions (i.e. Cases 2A, 2B & 2C) when the
flowline will be flowing 4.3 Mmscfd, the maximum fluid velocity and erosional
velocity are 1.2 m/s and 9.2 m/s respectively. See Figure 4 below.

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Erosional Velocity limits of

fluid @26mmscfd

Fluid Velocity@26mmscfd

Figure 3: Flowline Fluid velocity and Erosional Velocity at Flowrate of

26MMSCFD (Cases 1A, 1B and 1C).

Erosional Velocity limits of

fluid @4.3mmscfd

Fluid Velocity@ 4.3mmscfd

Figure 4: Flowline Fluid velocity and Erosional Velocity at Flowrate of

4.3 MMSCFD, (Cases 2A, 2B and 2C).

8.4 Heat Exchanger (E-100) and (H-1810) Sizing

The sizing case for the Heat Exchangers (E-100) and (H-1810) is Case 1A which
is 26 Mmsfcd of gas in the tube side. To maintain a temperature above its

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hydrate formation temperature of 18.9oC and 14.1oC, the well stream is

heated up to 44oC and 50oC respectively.
This result in an overall heat exchanger duty of 376.4 kW for (E-100), 330.5 kW
for (H-1810) and 705.3kW at the firetube (burner) of the water bath heater.
To achieve this outlet temperatures of 44oC and 50oC in the heat exchangers,
a hot water rate of 20946.77 kg/hr (21.66m3/hr) is required to be maintained in
the water loop. The hot water enters E-100 at 77.02oC and exit at 62.14 oC
.This is heated up at the firetube of the H-1810 to 90oC for effective heat
exchange to the well stream.

8.5 XHP Separator (V-105)

The existing XHP Separator is rated to handle 13MMSCFD of Eriemu Well-11T
fluid. This results in 4.29 MMSCFD of flashed off gas and 1.1 bpd of liquid at the
liquid leg.

8.6 Low Temperature Studies

The scenarios that determine the LDT of piping and flowline are Start-up and
depressurization / blowdown.

8.6.1 Start-Up
Option 1: During back start, pressure decreases across the (100-FCV-106) and
(100-FCV-105) from 195barg upstream to 0barg downstream (see figure 1).
The LDT related to this scenario has been calculated using an adiabatic flash
of the entire composition and assuming an ambient temperature of 18oC
(conservative approach). This results in an LDT of -74oC downstream of both
valves.
This is a very conservative approach that considers the flowline as infinite. In
reality, long before the pipe wall temperature reaches -74oC, the gas
upstream (100-FCV-106) and (100-FCV-105) shall be at normal flowing
temperature of (22.84oC), leading to a minimum temperature of -65.5oC.
Option 2: The back pressurization of piping downstream (100-FCV-106) and
(100-FCV-105) using fuel gas to 10barg during black start set the pressure
downstream (100-FCV-105) to 10 barg. This results in an LDT of -63.4oC
downstream of both valves, assuming conservative ambient temperature of
18oC. With the Well fluid gas flowing at a temperature of 23.2oC at upstream
of the (100-FCV-106) and (100-FCV-105), leads to a LDT of -55.7oC

8.6.2 Depressurization / Blowdown

Depressurization / blowdown of the flowline shall be done via globe valves
100-HCV-001 and 100-HCV-002, with restriction orifices (see figure 1). The LDT

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related to this scenario has been calculated using an adiabatic flash of the
entire composition and assuming an ambient temperature of 18oC
(conservative approach).
The blowdown was done for 4 hours with an orifice area of 7.77 mm2 and the
peakflow calculated is 1070 kg/h, while LDT calculated for downstream and
upstream piping (100-HCV-002) is -66.8oC and 17.69oC.

Figure 5: Depresurization Summary for the Flowline

The blowdown of piping between (100-UZV-111) and (100-XZV-107) with a

distance of 20.3m was determined.
The blowdown was done for 6 minutes with an orifice area of 7.47 mm2 and
the peak flow calculated is 1029 kg/h while the calculated LDT for the piping
between (100-UZV-111) and (100-XZV-107) after depressurization is 18.9oC. The
calculated LDT for the piping downstream the (100-HCV-001) after blowdown
is -75oC (See Figure 1).

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Figure 6: Depresurization Summary for the piping between (100-UZV-111) and

(100-XZV-107)

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9.0 CONCLUSION AND RECOMMENDATIONS

A two stage heating of Eriemu fluid in the shell and tube heat exchanger (E-
100) and Water bath heater (H-1810) has succeeded in reducing the heat
load (duty) of the heaters and subsequently its inherent economic and
operation challenges.
In all back start-up scenarios, cryogenic condition will exist in the piping
downstream (100-FCV-106) and (100-FCV-105) considering the calculated
LDT values of between -65.5oC to -55.7oC.
Based on depressurization studies carried out, there are no low temperature
issues for the flowline and piping to the XHP separator. Low temperature
issues will exist in the piping downstream the (100-HCV-001) and (100-HCV-
002).
It is recommended that:
The flowline to be blowdown for maximum of 4 hours because an increase in
the time will reduce the pressure and a vacuum pressure will be experienced
after orifice valve.
The hot water system should be started up first before opening up the well to
avoid the need to change piping material downstream (100-FCV-106) and
(100-FCV-105) to a low temperature material. This will make it possible to
make use of carbon steel instead of Low Temperature material that will
impact heavily on the CAPEX.
Austenitic stainless steel should be used as the piping material downstream
(100-HCV-002) and (100-HCV-001) respectively based on depressurization
studies carried out.

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10.0 REFERENCE
1. Design Report of Eriemu Well 11T Surface Facility over-pressure
Protection Project, FOP-TPEF-ERIF1-PX8380-00001-000
2. Eriemu Flowstation PEFS For Wellhead 11t (Gas Well), OML30-ERI-PRS-
DRG-00040-01_A01
3. Eriemu Flowstation PFD For Inlet Manifold and Process Facilities Tie-In,
OML30-ERI-PRS-DRG-00030-01_A01
4. Eriemu Flowstation PEFS For Inlet Manifold and ESD Valves, OML30-ERI-
PRS-DRG-00040-02_A01
5. API 14E_Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems, 5th Edition.
6. Condensate study report [Heritage Energy Eriemu-11T Recomb-final
rep]

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APPENDIX: Process Simulation Flow Diagram (PFD)

Appendix i: Eriemu Well 11t Simulation
Appendix ii: Eriemu Well 11t Flowline and Facilities Simulation for (Case 1)
Appendix iii: Eriemu Well 11t Flowline and Facilities Simulation for (Case 2)

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Appendix I: Eriemu Well 11t Simulation

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Appendix II: Eriemu Well 11t Flowline and Facilities Simulation for (Case 1)

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Appendix III: Eriemu Well 11t Flowline and Facilities Simulation for (Case 2)

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