gas plant

NEW GAS PLANT PROJECTTP REV. PAGE:

TABLE OF CONTENTS

1- INTRODUCTION

2- Scope of work

3- SITE DATA

3.1- Climate

3.1.1-Location

3.1.2-Elevation:

3.1.3- Atmosphere:

3.1.4- Temperatures:

3.1.5- Wind:

3.1.6- Humidity:

3.1.7- Rainfall:

3.1.8- Earth Quake:

4- APPLICABLE CODES, STANDARDS AND PRACTICE

5- Basis of Design

5.1- Feed Composition & Rates

5.1.1- Feed Gas Composition & Rates

5.1.2- Sour Feed Condensate Composition & Rates

5.2- Process Description

5.2.1- Gas Stream in Gas Pant

5.2.2- Condensate Stream to the Stabilizer

5.3-Turndown Requirements

6- PFDs with Heat & Material Balances


7- Preliminary P&IDs

8- Tie-in Points

8.1-Feed Raw Gas

8.2-Condensate Feed

8.3-Naphtha Rundown to Storage

8.4-C3

8.5-LPG

8.6-Sales Gas

8.7-Potable water

8.8-Fire water

8.9-Cable power

9- Special Considerations

9.1-Waxy Condensate

9.2-Desalter System;

10- Plant Performance Test & Process Guarantees

10.1- Plant Throughput

10.2- Plant Production

10.2.1-Feed at Design Rate

10.2.1.1- Raw Gas

10.2.1.2-Condensate to stabilizer

10.2.2- Raw Gas and Condensate Feed at Lower than

Design Rate

10.2.2.1- Raw Gas

10.2.2.2- Condensate To the Stabilizer

10.2.3-Product Specification

10.2.3.1- C3 Specification

10.2.3.2-LPGspecification


10.2.3.3-Sales Gas

10.2.3.4-Stable Condensate (Naphtha)Specification

10.2.3.5- Stabilizer production specification

11-Process Calculations

12.1-Process Simulations

12.2-Flare System Design

12-Subsystems And Utilities

12.1- Process Control System PCS

12.2- Telecommunications and Security Systems

12.3- Electrical Network

12.4- Propane Refrigeration

12.5- Heating Oil Unit

12.6- Flare and blow down

12.7- Instrument air system

12.8- Fire water and water cooling system

12.9- Fuel gas system

12.10- Draining system

12.11- POTABLE WATER

12.12-Inert or Purge Gas

12.13-Heating, Ventilating and Air Conditioning (HVAC)

12.14- Instr. Air system

13-Civil Design

14-Summary


1- INTRODUCTION

Sirte Oil Company, for Production Manufacturing of Oil and Gas plans, is

required technical and project Management services to the New Gas

Plant project up to the front end engineering design to build new Gas

Plant to replace the existing gas plant built in 1967 consist from two

trails, the capacity for each one is 250000 MMSCFD, this gas plant

handling the raw gas from Naser, Wadi, Jebel, lehib and raguba

facilities and the sour condensate from Attahady and Hateba…..

facilities at the field, the composition and the amount of the raw gas

clear as per the table 1.The composition and the amount of the sour

condensate in the table 2. The product from the gas plant as per the

table 3. Since this gas plant was constructed in years 1967 As badly

weathered affected and damaged by a severe corrosive and generally

hostile environment (rough sea and sand storms), the lifetime for this

gas plan is roughly finished, so its required to build new gas plant

able to replace this gas plant and handling the raw gas from Naser,

Wadi, Jebel, lehib and raguba facilities at the field with new Gas

Plant capacity f 150 MMSCFD. We take in our consideration the

production capacity of 2015 and 2016.


2- Scope of work

The scope of this document is providing the basic process

information to enable the consultant services engineering company

to provide technical and project Management services to the New

Gas Plant project up to the award of Front End Engineering Design

and include the following:

i. Conceptual design studies including evaluation of process licensors.

ii. Evaluation of process options.

iii. Engineering studies including safety and environmental assessments.

iv. Project cost estimation.

v. Planning and schedule assessment.

vi. Technical and control documentation for FEED tender

prequalification and bid


3- SITE DATA

3.1- Climate

3.1.1-Location

The Gas Plant is located at Marsa El Brega, which is right on

the coast of the Gulf of Sirte. There is a main road that links

Brega with Tripoli to the west and Benghazi to the east.

Marsa El Brega has port facilities of international standards.

The environmental conditions for the equipment will be open

air in a salt laden corrosive seacoast atmosphere with strong

winds blowing fine sand, high solar radiation and with

occasional torrential rains. Moisture condensation is

experienced on various surfaces at night. The atmosphere

may contain traces of hydrogen sulphide and ammonia from

time to time. The subsoil contains salt and sulphates.

The map location has been attached.

3.1.2-Elevation:

3 meter above sea level.

Attached site location layout

3.1.3- Atmosphere:

Sea side, very corrosive, salty,

occasionally very humid, salty and dusty.

3.1.4- Temperatures:

High : 95 to 142 F (140 F, Extreme)


Low : +41 to 50 F (32 F, Extreme)

3.1.5- Wind:

Prevailing direction : from N-NWMean velocity : 18 to 35 mph.Design : 90 mph.

Particulates born : by sand storms (up to 15days per year)

3.1.6- Humidity:

High : 100% (mostly in winter, Nov. to Feb.)

Low : 30 to 40% Average : 70%

3.1.7- Rainfall:

Annual : 16.7 in , max. Monthly : 6.6 in, max. Hourly : 1in, max. Stormy : 1in /hr for 9hrs.

3.1.7- Earth Quake:

Design: Zone III, as per UBC


4- APPLICABLE CODES, STANDARDS AND PRACTICE

The latest revision of the concerning codes, standards, directives and

practices of below listed National and International Institutes,

Associations and Organizations, shall be applied in the execution of

this project:

NOC-GES. : General Eng. Specifications of Libyan National

Oil Company.

ISA : Instrumentation Standards Association

API : American Petroleum Institute

NFPA /NFC : National Fire Protection Associations /

National Fire Codes

FEMA : Federal Emergency Management Agency

EMI : Emergency Management Institute

OCIMF : Oil Companies International Marine Forum

IMO : International Maritime Organization

ISO : International Standard Organization

IEC : International Electro technical Commissioner

WHO : World Health Organization

OSHA : Occupational Safety and Health Administration

ASME/ANSI : American Society of Mechanical Engineers

American National Standard Institute

ASTM : American Society for Testing and Materials

AWS : American Welding Society.


NACE : National Association of Corrosion Engineers

SSPC : Steel Structures Painting Council

SOC-BP : Basic Practice of Sirte Oil Company

5- Basis of Design

5.1- Feed Composition & Rates

5.1.1- Feed Sour Gas Composition & Rates

The Raw Gas produced from field facilities Naser, Wadi, Jebel, lehib

and raguba Facilities, these five raw gas products will combined in one

stream to feed the new Gas Plant at one time the composition of the

Raw gas from field facilities as indicated below.

The Gas Plant must be designed to process the companied gas at feed

rate of 150 MMSCFD where we put in the consideration the future

increasing of the production.

The gas should be treated using MDEA technology where we used this

technology in the existing plant unless the consultant company

suggests better solution, depending on the expected H2S and CO2 in

the feed Raw Gas

The production of the gas plant will be Treated Gas, C3, LPG and

Condensate.

Treated Gas will be sent to Petrochemical or Coastal Pipeline

C3 will send to the existing Storage Tanks, where we already using it.

LPG will send to the existing Storage Tanks where it already exists


The Condensate will send to the existing tanks.

We will use existing storages unless consultant suggests extra storage

and company agree

The composition of the Raw Gas from Naser, wadi, Jebel, Lehib, raguba and

combined raw gas from the field Facilities.

Component Raw Gas

From Naser

Raw Gas

From Wadi

Raw Gas

From Jebel

Raw Gas From

Lehib

Raw Gas

From

Raguba

Actual

common

Raw Gas

Nitrogen 0.206739 0.0045 0.005859 0.014000 0.010562 0.021245

CO2 0.08976 0.060100 0.001313 0.049200 0.016142 0.027706

H2S 0.013837 0.0000 0.000000 0.0000 0.000000 0.000820

H2O 0.013837 0.0000 0.000000 0.00000 0.000000 0.004888

Methane 0.582533 0.591300 0.797677 0.744600 0.695297 0.735589

Ethane 0.119811 0.1700 0.113232 0.109600 0.147868 0.118870

Propane 0.029627 0.091400 0.05101 0.046000 0.085492 0.053131

i-Butane 0.005535 0.018600 0.007071 0.010000 0.013153 0.009500

n-Butane 0.005372 0.031900 0.013333 0.014200 0.021921 0.015282

i-Pentane 0.0002574 0.01170 0.003535 0.004700 0.003587 0.004558

n-Pentane 0.001202 0.009100 0.002828 0.004400 0.001993 0.003757

n-Hexane 0.001317 0.005500 0.002222 0.003300 0.003986 0.002988

n-Heptane 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000

n-Octane 0.001668 0.005900 0.002828 0.0000000 0.000000 0.001666

n-Nonane 0.0000000 0.000000 0.000000 0.0000000 0.000000 0.000000

Total 100.00 100.00 100 100 100.00 100.00


Average

Temperatur

85 85 85 85 85

Average

Pressure(psi

290 290 290 290 290

Flow

Table 1

5.1.2- Sour Feed Condensate Composition & Rates

The condensate produced from field facilities Attahady, Hateiba

….Facilities, these condensate products will combined in one stream to

feed the stabilizer in the new Gas Plant at one time.

The maximum condensate feed rate from the field facilities to the

Stabilizer is expected to be 20 MBPD. The design feed rate to the

Stabilizer should be 30 MBPD.

The normal operating pressure of the condensate at the inlet to the

stabilizer is between ….. psia and …… psia, and the average

temperature is between 55°-90° F, depending on winter and summer

conditions. The average temperature is expected to be around 70 F.

The condensate stream from time to time, could contains free water

with a high salt content ( the possibility to utilize the existing new

Desalter should be checked, to remove any trace of water and salt that

may be present in the condensate , we attached the desalter data sheet,

P&ID and other related drawing).

We have to be sure that the condensate is always at a safe operating

margin above the condensate bubble point pressure to prevent flashing

of the condensate.

Composition of the condensate as it’s attached in the table 2

There are two feed compositions that need to be considered. These are:


Heavy Case Sour Condensate with heavy composition. Where in this

case will be more bottom condensate production and more load on the

bottom Stabilizer re-boiler, and bottom pumps.

Light Case Sour Condensate with light composition. Where in this

case will be more top stabilizer product and more load on the overhead

gas compressor.

The production of the stabilizer will be stable condensate (naphtha ),

and Gas where it will directed to combined raw gas feed, to treated in

the gas plant.

The composition of the raw condensate from Attahady and other Facilities.

Component Condensate from Attahady Condensate from others Facilities

Nitrogen 0.000 0.000699

CO2 0.013401 0.012077

H2S 0.00000 0.001996

H2O 0.000000 0.000000

Methane 0.0888809 0.070466

Ethane 0.042304 0.09948

Propane 0.086609 0.141731

i-Butane 0.041504 0.060285

n-Butane 0.048405 0.120571

i-Pentane 0.048205 0.090428

n-Pentane 0.034903 0.090428

n-Hexane 0.077408 0.140633

n-Heptane 0.086609 0.040024

n-Octane 0.081108 0.080347

n-Nonane 0.062106 0.030143


n-Decane 0.075208 0.040224

n-C11 0.032003 0.000000

n-C12 0.024402 0.000000

n-C13 0.026603 0.000000

n-C14 0.019202 0.000000

n-C15 0.017702 0.000000

n-C16 0.013201 0.000000

n-C17 0.012001 0.000000

n-C18 0.010601 0.000000

n-C19 0.009601 0.000000

n-C20 0.009201 0.000000

n-C21 0.005501 0.000000

n-C22 0.005201 0.000000

n-C23 0.00460 0.000000

n-C24 0.004200 0.000000

n-C25 0.003800 0.000000

n-C26 0.002700 0.000000

n-C27 0.002200 0.000000

n-C28 0.001800 0.000000

n-C29 0.001600 0.000000

n-C30 0.007301 0.000000

Total 100.00 100.00

Average Temperature, ( F)

Average Pressure(psia) 500

Flow 20 MBPD 12.5 MBPD

Table 2


The heavy and light sour condensate as its clear in the

table below.

5.2- Process Description

5.2.1- Gas Stream in Gas Pant

The raw gas from Naser, Wadi, Jebel, Lehib, Raguba and other

facilities, should combined in on line, and delivered to compressors

unit to increase the pressure up to 405 psia in first compressing stage,

in second compressing stage to about 640 psia. Each Compressor

should be provided with suction and discharge drum also before each

discharge drum heat exchanger( air cooler fan ) should be provided, to

cool down the stream and enable better removing the humidity and the

condensate from the Gas stream. Condensate should be collected from

all suctions and discharges drums to be delivered finally to the

stabilizer unit.

Consultant Engineering should advice if compressing the raw gas is

better to be done in one stage or two stage. Compressors to Gas

turban or electrical powered motor.

Gas with pressure about 640 should be delivered to the gas treatment

unit, to remove H2S and CO2. Company prefer to use MDEA

treatment technology, where the company used to use this technology,

in the existing Gas Plant, unless the consultant engineering company

advice with different technology, this will be subjected to the

availability of the H2S and CO2 in the raw gas and the selectivity of

the advised technology to H2S and CO2. Any changes to other


technology should be discussed with the SOC, to get agreement from

the SOC.

Sweet gas from MDEA treating unit will be cooled down by

exchanging the heat with cooled gas from after propane chiller drum by

heat exchanger, the sweet gas stream after the heat exchanger, will

enter the separating drum before the propane chiller to separate the

water and the condensate, the condensate will delivered to the De

Ethanizer as part of De-Ethanizer feed. Sweet gas from the top of the

separator will be directed to the Propane Chiller, Chiller should reduce

the stream temperature up to about 20 F or 0 F or -20 F, Consultant

Engineering Company should do their study to find out the

optimum cooling temperature at the outlet of the chiller, where it

will affect the product specification. (Company is preferring to have

Propane chiller, unless the Consultant Engineering Company advice

with better option so that should be discussed with the SOC to be

approved).

Sweet gas stream after propane chiller, will be directed to separator

drum, to separate the condensate and any trace of water, the sweet gas

from the top of the separator, will be directed to the heat exchanger, as

coolant flow, and cool down the sweet stream going to the separation

drum before the chiller, as first stage of cooling, before the propane

chiller, the sweet gas stream after the heat exchanger will be deliver it

to the coastal pipeline or to the petrochemical as sweet gas products.

The condensate from the separation drum, after propane chiller will be

directed to the heat exchanger, to be heated up and cool down the

propane in the chiller unit. The condensate stream after heat exchanger,

will be mixed with the condensate from the separation drum before the


propane chiller and both streams will be delivered in one stream as feed

to the De Ethanizer unit, after reducing the stream pressure from about

585 psia to about 505 psia.

The re-boiler at the De-Ethanizer column will use hot oil as heating

effluent, unless the Consultant Engineering Company will advice in

different heating agent, if Consultant engineering company have

different advice should be discussed with the company f or approval.

The overhead stream at the De-Ethanizer will be cooled by propane

cooler up to 20 or 23 F (the consultant engineering company should

make their study to find out the optimum cooling temperature and

condition at the De-Ethanazer column) the stream at the top of the

De-Ethanizer will be directed to the separator to separate the C1& C2

gas, and liquid to be used as reflex, The C1& C2 stream from the top

products stream of the De-Ethanizer where this stream pressure about

500 psia and temperature is about 25F ( this gas stream could be used

as coolant to the top of De-Propanizer column stream, consultant

engineering to check this possibility where it could be more

efficient) will be directed to companied with the suction side of the

second compression stage.

The condensate at the bottom of the De-Ethanizer will be delivered to

the De-propanizer column, after reducing the condensate stream

pressure from about 500 psia to about 300 psia, where propane should

be separated from this condensate stream at the De-Propanizer .

The boiler at the bottom of De-Propanizer Column should use heated

oil as heating effluent unless Consultant engineering advice

different agent (this should be discussed with the company for

approval).


The De-PropanIzer column conditions should be optimized to achieve

the most possible purity of the C3.

The overhead stream at the top of the De-Propanizer should be cooled

down by the air heat exchanger or by the product of the top of De-

Ethanizer, as consultant will advice. Part of this stream will be used

as reflex to control the top column temperature and the rest will be the

Propane top product.

The propane will be delivered to the existing storage tanks.

The condensate at the bottom of the De-Propanizer should be delivered

to the De-Butanaizer after reducing the stream pressure from about 300

psia to about 100 psia, again the boiler at the bottom of the De-

Butanaizer, should use hot oil as heating agent, unless consultant

engineering advice deferent agent. The overhead produced at the top

of the De-Butanaizer column will cooled down by air cooler. After

cooling the overhead stream will be directed to the separator, part of

the LPG will be used as reflex, to control the top column temperature,

the rest will be delivered to the existing storage tanks, the bottom

Naphtha product of the De-Butanaizer column will be pumped to

combined with the Stabilizer naphtha product after the stabilizer

bottom product pump before the air cooler, and delivered to the

existing storage.

5.2.2- Condensate Stream to the Stabilizer

The Stabilizer column expected to operate at a pressure level which

results in a tower bottoms temperature which will comply with the

limitations imposed by the temperature of the hot oil of the bottom re-


boiler ( hot oil in the re-boiler will be used as heating agent unless

the consultant engineering will advice with deferent heating agent)

and the fact that no cooling water will be available. The latter

limitation results in a higher naphtha rundown temperature to storage.

This, in turn, necessitates a lower allowable RVP value to prevent

naphtha flashing in the atmospheric storage tanks.

Process description for both cases heavy and light condensate will be

typical, the different in the process parameters and condition.

The condensate feed to the Stabilizer will split into a cold feed and a

hot feed. The Stabilizer column has no-refluxed. The cold feed, enters

through control valve to the top tray as reflux, the remainder of the feed

will passes through another control valve to be heated in the

feed/bottoms exchanger, this two control valves should be provided

with ratio controller to vary the ratio of the cold to hot feed, as desired.

The condensate streams from the bottom of suction and discharge

compressors drums, will combined with stabilizer feed stream, the feed

bottoms exchanger will exchange the heat between the bottom feed and

the bottom products, the outlet exchanger stream feed temperature will

be controlled by controlling the product stream at the bypass line of the

heat exchanger. The hot feed enters the Stabilizer column at tray

should be specified by the consultant, the product quality should be

monitored. Hence, it is important to design the facility such that the

operating parameters such as the hot to cold feed ratio and the feed

temperature to the Stabilizer can be maintained the same, regardless of

the feed composition, to simplify the stabilizer operation. The

condensate from the bottom of the stabilizer, after the heat exchanger,

and after the stabilizer bottom pump, will companied with the naphtha


products from the bottom of the De-Butanaizer ( Part of this Stream

could be used to heat up the feed condensate before the desalter, where

we face presence of wax in the feed condensate, where this wax in low

temperature could create problems in the desalter. the feed condensate

at the inlet of the deselter should be about 90 F ) and directed to the

existing storages after cooling by air cooler, and inject suitable

chemicals by the chemical injection kids mounted close to the outlet

product condensate (Naphtha)line.

The stabilizer overhead gas pressure, will be controlled by control

valve, and directed to the compressor suction drum to separate the

condensate, the condensate should be delivered back to the stabilizer

feed condensate, the gas will be pressurized (to pressure more than the

pressure at the companied feed raw gas at the inlet of Gas plant), by

compressor and cooled down by air cooler, before the discharge drum,

to separate the condensate, and any trace of water. Separated

condensate will be delivered to the stabilizer inlet feed.

The gas will be delivered to combine with the raw gas, at the inlet of

the gas plant.

W have attached the simple process flow diagram for the Gas Plant

including the Stabilizer, and the relation in between.

5.3-Turndown Requirements

The gas plant and stabilizer unit may not operate at this high feed rate

all the time. Therefore, whenever the feed rate is lower, the units shall

be capable of processing the raw gas, at the same efficiency in the gas

plant, also condensate at stabilizer unit.

The gas plant and stabilizer unit shall be able to operate with a feed rate

down to 25% of the design rate defined earlier. The gas plant shall


operate in the range 150 MMSCFD down to 47.5 MMSCFD, and the

stabilizer shall be operated 30 MBPD down to 7.5 MBPD of feed rate

without loss of efficiency.

6- PFDs with Heat & Material Balances

Process Flow Diagrams with heat and material balances for the Gas

Plant also for stabilizer with the two cases.

a) Heavy Case

b) Light Case

Should be carried by the consultant engineering, the process should be

optimized to the optimum design criteria.

The main objective should be to maximize the C3 and LPG from the

raw gas in the gas plant, produce Sales Gas, C3, LPG and naphtha

within the specification, while minimizing the utility consumption. It

should be borne in mind, that the Gas Plant and the Stabilizer will

operate in parallel and continually, also we should be able to operate

one of them at the time. The PFD should be completed with heat and

material balance table for each of the mentioned referenced cases.

Consultant engineering company to provide, optimum process scheme

for an economic viewpoint and from simplicity and ease of operation.

We have attached simple PFD for your reference.

7- Preliminary P&IDs


Preliminary P&IDs should basically show the major control loops and

provides an insight into the way wants to control and operate the Gas

plant and the Stabilizer. Preliminary hydraulic calculations should be

carried out.

8- Tie-in Points

The design and Process operating conditions at the tie-in points for the

major process streams in the Gas Plant and Stabilizer are defined as

below:

8.1-Feed Raw Gas

The compositions and the design & process operation conditions of the

feed Raw Gas at the tie-in point:

Raw Gas operating pressure at the tie-in point ………psia

Raw Gas operating temperature ………….. F Average

Pipe Design pressure at the tie-in …… psia

Pipe design temperature at the tie-in …… F

Pipe diameter at the tie-in …………..in

Location of the tie-in point clear in the attached P&ID and layout

drawing no

Raw gas composition as it’s in the attached table 1.

8.2-Condensate Feed

The compositions and the process operation conditions of the feed

condensate at the tie-in point

Operating pressure …………

psia

Pipe design pressure for the pipe ………psia


Operating Temperature is 70 F Average

Design temperature for is …. F

Pipe diameter at the tie-in ……………in

Location of the tie-in point clear in the attached P&ID and

layout drawing no

The compositions of the condensate feed attached to the docuent in

table table 2.

8.3Naphtha Rundown to Storage


Naphtha rundown to storage at the tie-in point:

Tie-in point design pressure ………………………….psia

Tie-in point operating pressure ………………………….psia

Tie-in point operating temperature ………………… F.

Tie-in point design temperature …………………… F

Pipe diameter at the tie-in point is …………………in


layout drawing no

Compositions of the Naphtha Rundown to the storage as its clear in the Product Specification section.

8.4-C3


C3 to storage at the tie-in point:



Tie-in point operating temperature …………………… F





layout drawing no

Compositions of the C3 to the storage as its clear in the Product

Specification section

8.5-LPG







layout drawing no

Composition of the LPG to the storage as its clear in the Product

Specification section

8.6-Sales Gas


Sales Gas at the tie-in point:








layout drawing no

Compositions of the Sales Gas to the storage as its clear in the

Product Specification section

8.7-Potable water

Design condition and location of the Potable water


Tie-in point design temperature ……………..………… F

Pipe diameter at the tie-in point is …………….…………in

Tie-in Operating pressure.…………………………….psia

Tie-in Operating temperature……..………………… F


layout drawing no

8.8-Fire water

Design condition and location of the Fire water


Tie-in point design temperature ……………..………… F

Pipe diameter at the tie-in point is …………….…………in

Tie-in Operating pressure…………………………….psia

Tie-in Operating temperature ……..………………… F


layout drawing no

8.9-Cable power


9- Special Considerations

9.1-Waxy Condensate

The condensate from Attahaddy field, contains between 7-10 wt% wax,

as determined by analytical method UOP 46, carried out on

atmospheric condensate sample, with the light ends flashed off.

The waxy Attahaddy condensate flows, in the main 16” condensate

pipeline from the field facilities to Brega. A paraffin dispersant

chemical, EC-6002A supplied by Nalco, is added at Attahaddy plant

facility, to inhibit the potential of wax building up in the 16” pipeline.

The chemical acts as a “surfactant”. It coats the wax particles, and

prevents them from agglomerating and minimizes their adherence to

the pipe wall.

Since Nalco chemical EC-6002A does not depress the pour point of the

waxy Attahaddy condensate, a suitable pour point depressant is

currently being sought to overcome any potential problem that may

surface with the onset of winter. The cooler ambient temperatures are

likely to fall below the natural pour point of the waxy condensate, and

the naphtha product. Naphtha product is also a concern since wax that

accompanies the Attahaddy condensate ends up, after processing, in the

naphtha product to storage.

During the design of the facility the presence of wax should be

considered. For example, all instruments, sight glasses, dead legs, etc,

wherein wax is likely to be encountered/deposited must be protected

by, for example, electric tracing. Pressure gauges must be protected by


diaphragms to prevent wax from coming into contact with the gauge

internals.

Designer should consider skid mounted chemical injection system

comprising of suitably sized tank , pumps one in operation and stand

by, instrumentation, lines, etc to enable a wax dispersant chemical or a

pour point depressant chemical to be injected to maintain specific

concentration of the chemical in the naphtha product to storage.

9.2-Desalter System;

The possibility to utilize the existing desalter system with capacity of

55 MBPD should be considered, the desalter system data sheet,

specification and P&ID and layout drawing attached to this document.

10- Plant Performance Test & Process Guarantees

The plant performance test should be carried out as below, this as per

SOC request. If Consultant Engineering Company advice with any

extra beneficiary requirement for SOC or any correction should

discussed with SOC.

The plant performance test, shall be carried out within six months,

from the date of transfer of custody and responsibility of the plant to

the COMPANY.

The performance test will be carried out by the COMPANY. The

performance test shall be of 72 hours continuous duration, or shorter at

the sole discretion of the COMPANY. The test shall evaluate/confirm

the performance of Compressors units, MDEA Gas Treatment unit


Propane chiller unit, the De-Ethanizer tower, De-Propanizer tower, De-

Butanizer tower, Operation, also the Stabilizer tower operating with

Heavy and Light feed compositions and a composition in-between, and

a feed rate between 150 MMSCFD and 37.5 MMSCFD for the Gas

Plant and 30MBPD and 7,5 MBPD, depending upon the availability of

the condensate for the stabilizer.

Detailed procedure for the performance tests shall be developed by

CONTRACTOR and will be reviewed and approved by the

COMPANY.

The performance tests shall be carried out in accordance with the

approved procedures in order to determine whether the plant performs

in accordance with the design. The performance tests shall not only

enable the evaluation and verification of the performance of the overall

plant but of each item of equipment within the plant.

CONTRACTOR may be present to witness the performance test.

Samples will be taken by the COMPANY’s operating personnel and

analyzed in the COMPANY’s laboratory. CONTRACTOR may choose

to carryout his own analysis. In this case COMPANY will take another

set of samples for the CONTRACTOR.

CONTRACTOR shall provide all necessary tools to carryout the tests.

New bombs shall be supplied by the CONTRACTOR. The number of

bombs provided shall correspond to the number of samples to be taken

over a 24 hour period. Should CONTRACTOR desire a second set of


samples to be taken for carrying out his own analysis, then he shall

supply his share of the bombs along with his own chromatograph.

The results of the analysis obtained by COMPANY shall then be

compared with the analysis results obtained by the CONTRACTOR. In

case of a large difference, samples shall be analyzed once more. Should

the difference still remain, then another two sets of samples shall be

taken and the procedure repeated again. If, at the end, the difference

still remains and in the event no agreement could be reached, then a

third party laboratory technician shall be brought to the site to carryout

the analysis. The third party technician shall be acceptable to both the

COMPANY and the CONTRACTOR.

The results obtained during the performance test shall be scrutinized by

the CONTRACTOR, and a detailed report issued on the subject by the

CONTRACTOR. Upon acceptance of the report and on the basis that

the performance test was indeed successful, COMPANY will issue the

provisional certificate.

It is recognized that exact duplication of the design conditions and

analyses serving the basis for guarantees may be improbable under

actual field conditions. Therefore, if actual conditions and analyses

vary from those used in the design calculations in sufficient degree to

influence the performance and efficiency of the plant, the gas feed and

condensate feed composition and rate obtained during the test run shall

be used as the basis for process calculations and the rerunning of the

computer simulation model, using the same program and method


utilized in the design of the plant, to determine the performance that

would have resulted and then comparing that to the actual test result. In

calculating performance in this manner, no operating conditions less

favorable than design shall be used if the conditions are less favorable

because of unsatisfactory operation or if insufficient

capacity/throughput is caused by the equipment installed by the

CONTRACTOR.

Should the performance test be deemed to be unsuccessful for reasons

attributable to the design of equipment items or units, the

CONTRACTOR shall take whatever remedial steps necessary to

correct or modify the defect to enable meeting of all the process

guarantees. In the event CONTRACTOR is unable or unsuccessful, the

CONTRACTOR shall be liable for these deficiencies as per the

Contract.

Once remedial actions are carried out by the CONTRACTOR to fix the

deficiencies, the performance test shall be repeated in its entirety.

Alternatively, at the sole discretion of the COMPANY, performance

test may be repeated only for the affected area or areas of the plant.

COMPANY will issue the provisional acceptance certificate once the

COMPANY is satisfied that the plant performs as per design and no

process related deficiencies exist and that all process guarantees are

met as per the terms of the Contract, and accepted by the COMPANY.

The overall performance of the plant shall be measured based on the

following:


10.1- Plant Throughput

While continuously producing on-specification products, the

throughput value shall be the feed rate to the plant of 150 MMSCFD

Gas and 30 MBPD the Heavy or Light Condensate taking into account

metering accuracy.

10.2- Plant Production

10.2.1-Feed at Design Rate

Based on the design Raw Gas rate of 150 MMSCFD and

Condensate at 30 MBPD to the Gas Plant and stabilizer the

following shall be the production rates for the C3product, the

LPG product, the Naphtha and the Sales Gas.

a) The C3 production figure shall be …X….taking into account

metering accuracy, based on the design Raw Gas and

Condensate flow. The temperature of the C3 product exiting

the C3 Product Cooler shall not exceed 137 F and pressure

297 Psia

b) The LPG production figure shall be …Y ….taking into

account metering accuracy based on the design Raw Gas and

Condensate flow. The temperature of the LPG product

exiting the LPG Product Cooler shall not exceed 142 F and

pressure 98 Psia

c) The Naphtha production figure shall be …Z….taking into

account metering accuracy, based on the design Raw Gas and

Condensate flow. The temperature of the Naphtha product


exiting the Naphtha Product Cooler shall not exceed 115 F

and pressure 100 Psia.

d) The Sales Gas Production figure shall be …M….. taking into

account metering accuracy, based on the design Raw Gas and

Condensate flow. The temperature of the Sales gas exiting

the sales gas heat exchanger product should be about 80 F

and pressure about 586psia.

10.2.2- Raw Gas and Condensate Feed at Lower than Design Rate

In the event the Raw Gas feed rate is lower than the design

value of 150 MMSCFD and 30 MBPD to the gas plantand

stabilizer, the production figures shall be :

a. For C3, the actual feed rate, times X/ design feed

b. For LPG, the actual feed rate, times Y/ design feed

c. For Naphtha, the actual feed rate, times Z/ design

d. For Sales Gas, the actual feed rate, times M/ design feed

The above in 10.2.1 and 10.2.2 should be applicable for the Gas

Plant without operating the stabilizer, stabilizer itself and all together

Gas Plant and stabilizer together.


10.2.3-Product Specification

10.2.3.1- C3 Specification

The LPG shall meet the following composition and condition:

Component C3

Nitrogen 0.000

CO2 0.000

H2S 0.000

H2O 0.000

Methane 0.000025

Ethane 0.020575

Propane 0.907009

i-Butane 0.057108

n-Butane 0.015246

i-Pentane 0.000030

n-Pentane 0.000006

n-Hexane 0.000000

n-Heptane 0.000000

n-Octane 0.000000

n-Nonane 0.000000

Total 100.00

Average Temperature, ( F) 137


Flow BPD 2856/

Table 3


10.2.3.2-LPG specification

The LPG shall meet the following composition and condition:

Component LPG

Nitrogen 0.000

CO2 0.000

H2S 0.000

H2O 0.000

Methane 0.000000

Ethane 0.00000

Propane 0.023166

i-Butane 0.289149

n-Butane 0.476872

i-Pentane 0.150718

n-Pentane 0.060069

n-Hexane 0.000025

n-Heptane 0.000000

n-Octane 0.000000

n-Nonane 0.000000

Total 100.00



Flow BPD 3423

Table 4


10.2.3.3-Sales Gas

The Sales Gas shall meet the following composition and condition:

Component Sales Gas

Nitrogen 0.021974

CO2 0.000

H2S 0.000

H2O 0.000

Methane 0.775864

Ethane 0.134985

Propane 0.051285

i-Butane 0.006835

n-Butane 0.007252

i-Pentane 0.000996

n-Pentane 0.000587

n-Hexane 0.000121

n-Heptane 0.000001

n-Octane 0.000000

n-Nonane 0.000000

Total 100.00



Flow MMSCFD 146.2

Table 5


10.2.3.4-Stable Condensate (Naphtha) Specification

The Stable Condensate (Naphtha) shall meet the following composition

and condition:

Component Condensate product (Naphtha)

Nitrogen 0.000000

CO2 0.000000

H2S 0.000000

H2O 0.000000

Methane 0.000000

Ethane 0.000000

Propane 0.000000

i-Butane 0.000043

n-Butane 0.000717

i-Pentane 0.158932

n-Pentane 0.362466

n-Hexane 0.459420

n-Heptane 0.018422

n-Octane 0.000000

n-Nonane 0.000000

Total 100.00



Flow BPD 976.9

RVP,psia(max)@ 100 F 13.5

Gravity, API (max) 90


Distillation, ASTM D86 Vol%vs Temperature F(min-Max)

10% 90min-160max

Table 6

10.2.3.5- Stabilizer production specification

The Stable Condensate (Naphtha) shall meet the following composition

and condition:

Component Condensate product (Naphtha)

Nitrogen 0.000000

CO2 0.000000

H2S 0.000000

H2O 0.000000

Methane 0.000000

Ethane 0.000001

Propane 0.000918

i-Butane 0.026537

n-Butane 0.077638

i-Pentane 0.092995

n-Pentane 0.085839

n-Hexane 0.159713

n-Heptane 0.098132

n-Octane 0.123230

n-Nonane 0.071988

n-Decane 0.089924

n-C11 0.025851

n-C12 0.019790

n-C13 0.021575


n-C14 0.015573

n-C15 0.014357

n-C16 0.010707

n-C17 0.009733

n-C18 0.008598

n-C19 0.007787

n-C20+ 0.039014

Total 100.00



Flow BPD 26460

RVP,psia(max)@ 100 F 13.5

Gravity, API (max) 90

Distillation, ASTM D86 Vol%vs Temperature F(min-Max)

10% 90min-160max

Table 7

11- Process Calculations

Consultant Engineering Company should carry out all

calculations in the Customary (Imperial) Units. Following

is a list of areas for which detailed calculations shall be

carried, as a minimum, meaning that the calculations

requirement shall not only be restricted to these areas.

11.1-Process Simulations

For process simulation work should use commercially

available program HYSYS. A complete set of the

simulation model computer diskettes shall be carried out

and for each case studied.


11.2-Flare System Design

All calculations for the design of the entire system should

be carried out. Computer programs, if used, should be

commercially available programs accepted by industry.

12- SUBSYSTEMS AND UTILITIES

12.1- PROCESS CONTROL SYSTEM PCS:

The Process Control System shall continuously monitor and control the

plant during start-up, normal operation, reduced rate operation, upsets,

and emergency shutdown.

The PCS shall include the following main systems:

I. Distributed Control System (DCS) - Provides primary process

control, monitoring, and data acquisition functions for the plant.

II. Emergency Shutdown System (ESD) - Provides protection of

personnel, environment, and equipment, through detection and

actuation of devices designed to lead the plant into a safe

condition.

III. Fire and Gas System (FGS) - Provides local and centralized

warning of personnel to handle fire and gas events, through

detection of gas leakage or fire.

IV. Machinery Monitoring System (MMS) – Provides machinery

protection for critical and major rotating equipment.


V. Compressor Control System (CCS) – Provides anti surge

protection and performance control for centrifugal compressors,

and turbine speed control.

VI. Packaged Equipment Controls - PLC or controllers dedicated to

modular equipment skids or particular process units, such as tank

farm management, custody transfer, pipeline leak detection,

Eluxyl process unit, etc.

12.2- Telecommunications and Security Systems

Telecommunication facilities and systems will be provided in order to provide all the required voice, data, video communications and security facilities for the Gas Plant

12.3- Electrical Network

The purpose of the electrical network is to distribute

power to supply all process, utilities, control and

communications systems. In addition, it must maintain the

emergency and essential supplies to critical equipment

should the main power supply fail, and provide

uninterruptible supplies to vital equipment where no

momentary breaks in supply can be tolerated.

Electrical System:

• Power Generation System

i. Main Power Supply System

ii. Emergency power generator system

iii. Uninterruptible Power Supplies (UPS)

iv. Battery and Battery Chargers/Rectifier Systems (DC

Systems)


• Power Distribution System

• Electrical Control System (ECS)

• Electrical Load Shedding (ELS)

• Lighting System (LTG)

• Lightning and Grounding Systems (LGS)

• Cathodic Protection System (CPS)

12.4- Propane Refrigeration

Propane refrigeration unit with sufficient capacity and

connection for future Gas plant should be considered. That

is if Consultant Engineering Company has no better

option.

12.5- Heating Oil Unit

New Heating Oil unit is required with sufficient capacity

and connection for future gas plant should be considered.

That is if Consultant Engineering Company has no better

option.

12.6- Flare and blow down

New Flare and Blow down system is required to be

sufficient and dedicated for the new gas Plant, connection

for future gas plant should be considered in the system

(The possibility to use the existing Flare and Blow down

system should be checked )

12.7- Instrument air system


New instrument air system, also the capacity increase for

future gas plant with connection for future gas Plant

should be considered

12.8- Fire water and water cooling system

Complete and sufficient Fire water system and water

cooling system with connections for future Gas Plant

should be consider (The source of the Fire water and

cooling water should be checked and should be mention)

12.9- Fuel gas system:

Fuel gas system should be provide for the new Gas Plant

as required considering the connection for future Gas

plant.

12.10- Draining system:

-Service drain

-Process drain

12.11- POTABLE WATER:

Desalinated sea water-Distillate available, tie-n point as its

clear above.

Operating pressure : 5 Bar g

Design pressure : 10 Bar g

12.12-Inert or Purge Gas:


New Nitrogen gas plant dedicated for the gas plant with

capacity enough for the gas plant. Piping net work should

be considered for the gas plant and connection for the

future new gas plant also the nitrogen plant should be

designed in the way we will be able to increase its

capacity.

12.13-Heating, Ventilating and Air Conditioning (HVAC)

Sufficient Heat ventilation and air condition should be

considered for all control buildings, also ventilation

system for process buildings.

12.14- Instr. Air system:

Design for new instrument air system with connection for

future extension of the gas plant should be consider also

the capacity increase for future gas plant.

13- Civil Design

This Specification should describe the Scope of Work for

Civil Works and Steel Structures for Gas Plant Project.

All the international codes and NOC specification shall be

considered as integral part of this specification, as well as

their addenda.


SUMMARY

Consultant Engineering Company should take into consideration all the

information in this document, if there is any better option than Propane

Refrigerant unit as cooling agent, Hot Oil as heating gent, Compressors to be

gas turbine engine or electrical powered with one compression stage or two

compression stages, or if there is any changes in the system as described in

this document to have better smooth and safe process with high productivity

and less capital cost and/or operation cost, should advice SOC.

Consultant Engineering to check if there is any extra information required,

SOC will provide it.

Consultant Engineering should do the conceptual studies, evaluate the

process options, considering safety and environmental assessments to obtain

the optimum design simulation, and cost estimation for this project, also

preparing the planning schedule.

The project cost should be discussed with SOC. If the project costs is

accepted by SOC then Consultant Engineering Company should go ahead

and proceed in the feed design tender prequalification and bidding.

gas plant

Documents

sales gas

gas stream

feed raw gas

purge gas

gas plans

existing gas plant

gas pant

new gas plant able