Oil & Gas Processing Plants

Design and Operation

Training Course

DGEP/SCR/ED/ECP - 24th March-4th April 2003

UTILITIES

DGEP/SCR/ED/ECP - 24th March-4th April 2003

GENERAL

Utility systems for oil and gas processing plants

include all facilities related to preparation and
distribution of:
-

fuel gas, fuel oil,

cooling water, refrigeration fluid,
hot oil, steam,
electric power,
utility and instrument air,
inert gas,
chemicals.

DGEP/SCR/ED/ECP

FUEL SYSTEM - GENERAL

The term fuel applies to both liquid fuels and gaseous

fuels. Fuel systems on E&P production installations can
be divided into four different categories:
-

fuel gas systems,

crude oil and residual fuel oil systems,
distillate liquid fuel systems,
aviation fuel systems.

Fuel systems include facilities for collection, preparation,

and distribution of fuel to users.
The commonly used fuel in oil and gas processing plants
is fuel gas. Fuel oil is only used for some emergency
equipment.

DGEP/SCR/ED/ECP

FUEL SYSTEM - FUEL GAS SYSTEM - USERS

Users of fuel gas:

- high pressure (HP) fuel gas:

HP: a range of 15 to 25 bar (g) is

today common for heavy-duty gas
turbine but for aircraft derivative
gas turbine a range of 25 to 30 bar
(g) (30 to 50 bar (g) in the future)
must be considered.

gas turbines of the electrical

power station (turbogenerators),
gas turbines to drive main pumps and (or) compressors;

- low pressure (LP) fuel gas (mean value = 4 bar (g)):

indirect fired heaters,
direct fired heaters (fire tube, furnaces, hot oil or hot water
heaters, ),
stripping gas,
flare or vent sweeping (or purge) gas,
inert gas generator,
power gas.

DGEP/SCR/ED/ECP

FUEL SYSTEM - FUEL GAS SYSTEM - USERS

POWER GAS
Item

CGC 320A
CGC 320B
CGC 320C
CGC 721
CGC 321
CGC 800A
CGC 800B
CGC 805
CGC 806
CGC 807A
CGC 807B
TOTAL (max.)

Pump
operating
status
(4)
NR
I
S
I
NR
NR
S
NR
NR
NR
S

Hydraulic/
motor
power
(kW)
9.0
9.0
9.0
0.5
1.0
0.1
0.1
10.0
0.1
0.3
0.3
39

Air cons.

Air cons.

Gas cons.

Gas cons.
rate

(SCFD)
(1)
320
320
320
21
60
11
11
350
10
20
20
1 463

Sm3/h

Sm3/h
(2)
495
495
495
32
93
17
17
542
15

(kg/h)
(3)
385
385
385
25
72
13
13
421
12

31
2 232

24
1 735

542
542
542
36
101
19
19
595
17
34
34
2 481

TOTAL (NR)
21
771
1 308
1 162
903
Notes:
(1) estimated
(2) gas consumption rate = 1.04/1.14 air cons. Rate
(3) W(kg/h) = P.V.MW/R.T; P=101.32 kPa; R=8.31m3.kPa/kgmol.K; MW=18.36; T=288K.
(4) NR: Normal running; S: Spare; I: Intermitent
FUEL GAS
Item
Description
Spec
C/I
cons. @
(1)
35C,
(kJ/kWh)
(-)
Efficiencies: 25%
XXX

XXX

14 500

TOTAL

DGEP/SCR/ED/ECP

Power gas or
electrical power

Equipment Fuel gas, Fuel gas, Fuel gas,

Power
design
design
design
case
case
case
(kw)
(kg/h)
(Sm3/h)
(Sm3/d)
39

12.16

15

372

39

12

15

372

FUEL SYSTEM - FUEL GAS SYSTEM - QUALITY

Quality:
- fuel gas must be free of liquids (free water, hydrocarbon
condensates) and solids (sand or clay dust, rust or iron
oxides, gas hydrates, ),
- to guarantee that fuel gas is free of liquids, fuel gas
temperature must be maintained at constant value (in a
range of 10C to 20C with a mean value of 15C above the
higher value of the water dew temperature and the
hydrocarbon dew temperature at user inlet flange
pressure,
- usually there is no specification for fuel gas temperature
at user inlet flange but it is recommended to maintain its
value constant below 100C,

DGEP/SCR/ED/ECP

FUEL SYSTEM - FUEL GAS SYSTEM - QUALITY

- fuel gas pressure at user inlet flange must be maintained

at required constant value defined by the user: gas
turbine, fired heater supplier, glycol regeneration unit,
- corrosive damage is due to the presence in the fuel gas of
corrosive agents:

DGEP/SCR/ED/ECP

hydrogen sulphide (H2S),

sulphur dioxide (SO2),
carbonyl sulphide (COS),
sulphur trioxide (SO3),
total sulphur and carbon dioxide (CO2) cause for gas turbine
elevated temperature corrosion of turbine nozzle and
blading materials and ambient temperature corrosion of
control valves and systems;

FUEL SYSTEM - FUEL GAS SYSTEM - QUALITY

- chlorides, sulphur and alkali metals, sodium, potassium,

calcium, vanadium, lithium and lead may be present in
either the gaseous phase or in the liquid and solid
contaminant and combine to form corrosive alkali metal
sulphates or chlorides during the combustion process.
Sulphur convert to sulphur trioxide in the gas turbine
combustion system and condense into sulphuric acid at
the liquid-vapour equilibrium temperature which is a
function of the SO3 concentration.
The purchaser must specify
concentration of corrosive agents
on the data sheets so that proper
precautions can be taken.

DGEP/SCR/ED/ECP

FUEL SYSTEM - FUEL GAS SYSTEM - QUALITY

- Lower (or Net) Heating Value (LHV):

heating value is the heat liberated by combustion of a fuel.
it is expressed in heat units per unit mass for liquid fuels but for
gaseous fuels it may be expressed on a mass, molar or volume
basis,
lower Heating Value (LHV) is the total heat produced by combustion
of the fuel less the latent heat contained in the water vapour
(produced by combustion) discharged as flue gas. As this latent
heat is not normally recovered, LHV represents the available heat;

- the Wobbe Index relates the heating value of a gas to its density
and is important for combustor design. The basic relation is:
WI = CV / (SG)1/2 where WI = Wobbe Index
CV = calorific value on volumetric basis, SG = specific gravity (with
respect to air)

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - QUALITY

Components
(-)

MW
(-)

N2
C1
C2
C3
iC4
nC4
iC5
nC5
nC6
nC7
nC8
nC9
nC10
H2S
H2O
CO2

[m]
28.013
16.043
30.07
44.097
58.124
58.124
72.151
72.151
86.178
100.205
114.232
128.259
142.286
34.076
18.015
44.01

Molar %
(%)

MW balance

Mole Vol.
(Nm3/kmol))

Mole Vol.

[m.%]

[V]
22.4
22.38
22.17
21.84
21.78
21.5
21.03
20.86
20.3
20.3
20.3
20.3
20.3
22.14
22.4
22.26

[m.V]

[3]
LHV

DGEP/SCR/ED/ECP

= [1]
= [1]/[3]
= [1]/[2]
= [1]/210.828628

=>
=>
=>
=>

[2]

kcal / kmol
kcal / kg
kcal / Nm3
BTU/SCF (Gas Ideal)

11

LHV
(kcal/kmol)
NGPSA
[LHV]
0
191 664
341 078
488 300
632 717
634 678
779 707
781 647
928 426
1 075 268
1 222 110
1 368 973
1 515 562
123 967
0
0

LHV
(kcal/kmol)
[m.LHV]

[1]

FUEL SYSTEM - FUEL GAS SYSTEM - QUANTITY

To determine the mass balance of the required fuel gas flow

rate the efficiencies values of apparatus as follows can be
adopted:
- indirect fired heaters: 60 %
- direct heaters: 70 % (fired heaters with only a radiant section)
80 % (fired heaters with a radiant and a convection
section or only a convection section)

- gas turbines: 20 to 30 % (according to gas turbine type)

- gas engines: 50 %
- CO2 generator: 0.08 Nm3 fuel gas /Nm3 inert gas

A contingency value must be added to the total flow rate

obtained with previous values:
- 20 % for a feasibility study,
- 15 % for a preproject.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EQUIPMENTS

Equipment of a fuel gas system:

- process flow diagram of fuel gas system depends on:
requirements of fuel gas users,
characteristics of available gas;

- available gas conditioning must produce the required quantity

of fuel gas at required quality (free of liquids, solids and
corrosive agents at user inlet flange) and produce sufficient
surge capacity,
- required characteristics of fuel gas are:
required constant pressure defined by the user (gas turbine, fire
heater suppliers),
constant temperature below 100C and above 10C to 20C of the
dew temperature (water & hydrocarbon),
free of solids.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

Fuel gas heater

(or electrical
heater)

Treated high pressure

gas (with sales gas or
more severe
specifications)

Main power generation

PC

HW

HP fuel gas
solids filter

Compressor turbines

Burners (glycol
regenerators, direct and
indirect fired heaters)

LC

HP flare header (purge)

HP fuel gas
receiver

PC

LP flare header (purge)

Flare pilot

LP fuel gas
receiver

LC

Blanket gas (drain,

sump, etc...

Concensate to crude
separator

Figure 2a - Example of utility flow diagram for fuel gas system.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

HP fuel gas
receiver
(optional)

Fuel gas heater

(or electrical
heater)

Main power generation

PC

Non-treated high
pressure gas (>70barg)
(from first stage
separator of a gas
reservoir stream

HW

HP fuel gas
solids filter

Burners (glycol
regenerators, direct and
indirect fired heaters)

PC
TC

Compressor turbines

LC

HP flare header (purge)

Hot/cold fuel
gas exchanger

PC

LC

LP flare header (purge)

Flare pilot

HP fuel gas
K.O. Drum

LP fuel gas
receiver

LC

Blanket gas (drain,

sump, etc...

Concensate to crude
separator

Figure 2b - Example of utility flow diagram for fuel gas system.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

HP fuel gas
receiver
(optional)

Fuel gas heater

(or electrical
heater)

Main power generation

PC

HW

HP fuel gas
solids filter

Compressor turbines

Burners (glycol
regenerators, direct and
indirect fired heaters)

PC
LC

TC

HP flare header (purge)

Associated gas (from first

stage crude separator)

PC

LC

LP flare header (purge)

Flare pilot

CW
Hot/cold fuel Fuel gas cooler
gas exchanger
(optional)
(optional)

HP fuel gas
K.O. Drum

LP fuel gas
receiver

LC

Blanket gas (drain,

sump, etc...

Concensate to crude
separator

Figure 2c - Example of utility flow diagram for fuel gas system.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

HP fuel gas
receiver
(optional)

Fuel gas heater

(or electrical
heater)

Main power generation

PC

HW

HP fuel gas
solids filter

Compressor turbines

Burners (glycol
regenerators, direct and
indirect fired heaters)

PC
LC

HP flare header (purge)

PC

LC

LP flare header (purge)

Flare pilot

Associated gas (from

compressor suction
scrubber or second
stage crude separator)

HP fuel gas
K.O. Drum

LP fuel gas
receiver

LC

Blanket gas (drain,

sump, etc...

Concensate to crude
separator

Figure 2d - Example of utility flow diagram for fuel gas system.

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

H2S
0.02 mol%
(200 ppm)

H2S
6 to
12 mol%

DGEP/SCR/ED/ECP

19

FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

28 barg
80C

9 barg
60C

LP Fuel gas:
195 000 Sm3/d
(7 MMSCFD)
HP Fuel gas:
650 000 Sm3/d
(23 MMSCFD)

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - FUEL GAS SYSTEM - EXAMPLE

Fuel Gas

Sweetening
for fuel gas

DGEP/SCR/ED/ECP

25

FUEL SYSTEM - DIESEL OIL SYSTEM - USERS

Typical users of diesel oil as a motive fuel are:

- dual fuel turbine generator sets ,
- dual fuel mechanical drive turbine sets,
- diesel engine driven fire pump sets fire water pump diesel
engines,
- diesel engine generator sets for emergency services,
black start and/or basic services emergency generators,
- diesel engine generator sets for drilling services,
- water heaters,
Average fuel consumption:
gas turbine = 350 g/(kW.hr)
- CO2 generator,
diesel engine = 200 to 250 g/(kW.hr)
- non-fuel uses.
diesel engine = 200 to 250 g/(kW.hr)
CO2 generator = 70 to 100g/Sm3 of inert gas.

DGEP/SCR/ED/ECP

26

FUEL SYSTEM - DIESEL OIL SYSTEM - USERS

Unit

ISO Base Load

(kW)

Specific Fuel
Consumption (1)
(g/kW.hr)

SOLAR
Saturn 20
Centaur 40S
Centaur 50S
Taurus 60S
Taurus 70S
Mars 90S
Mars 100S

1 210
3 515
4 345
5 200
6 844
9 285
10 695

350
300
290
280
260
270
260

500
1 270
1 530
1 720
2 130
2 980
3 320

General Electric
LM1600-PA
LM2500-PE
LM2500+(PK)
LM5000-PC
LM6000-PA

13 750
22 800
28 500
34 450
40 590

240
230
220
220
220

3 980
6 370
7 660
9 260
10 510

Nuovo Pignone
PGT2
PGT5
PGT10
PGT16
PGT25

2 000
5 220
10 220
13 750
22 450

340
320
270
240
230

810
2000
3 280
3 980
6 280

EGT
Hurricane
Typhoon5.3
Tornado
Tempest
Cyclone

1 662
5 252
6 730
7 736
12 912

350
280
270
280
240

690
1 740
2 160
2 640
3 730

Rolls Royce
Avon
RB211
Trent

14 580
27 210
51 190

300
230
210

5 290
7 600
12 700

Note 1: With LHV of 42 680 kJ/kg

DGEP/SCR/ED/ECP

27

Fuel Consumption
(litres/hr)

FUEL SYSTEM - DIESEL OIL SYSTEM - QUALITY

Quality
- for gas turbines should not exceed the accepted limits for
standard liquid fuel (for which LHV = 42 680 kJ/kg):
Sulphur (S) 10 g/kg x (LHV) / 42 680 kJ/kg,
Vanadium (V) 0.5 mg/kg x (LHV) / 42 680 kJ/kg,
Sodium plus Potassium (Na + K) 1.0 mg/kg x (LHV) / 42 680 kJ/kg,
Lead (Pb) 1.0 mg/kg x (LHV) / 42 680 kJ/kg,
Calcium (Ca) 2.0 mg/kg x (LHV) / 42 680 kJ/kg.

- for diesel engines:

Water and sediment levels
0.1%
Sulphur
0.4% wt

DGEP/SCR/ED/ECP

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FUEL SYSTEM - DIESEL OIL SYSTEM - QUALITY

- contamination commonly arises during transportation and

off-loading, particularly offshore. Contracts and
procedures shall be formulated so as to minimise this risk.

Pressure
- frequently the diesel oil end user has its own fuel oil pump
to feed the diesel into the burners/nozzles at the correct
pressure to ensure satisfactory fuel atomisation.

Temperature
- if the diesel oil pour point is less than 10 C below the
minimum ambient temperature, provision of diesel tank
heaters and the insulation and heat tracing of exposed
lines shall be considered.

DGEP/SCR/ED/ECP

29

FUEL SYSTEM - DIESEL OIL SYSTEM - EQUIPMENTS

Equipment of diesel oil system consist of:

- loading system,
- usually a metallic filter is installed on this transfer line,
- an atmospheric storage tank fed periodically by a truck or
a supply boat with a transfer line,
- a filtering system, between the storage tank and the
intermediate tank, composed of cartridge filters and
coalescer to separate solids and water contained in diesel
oil,
- sometimes centrifuge is used in filtering system,
- an atmospheric intermediate tank to store the filtered
diesel oil,

DGEP/SCR/ED/ECP

30

FUEL SYSTEM - DIESEL OIL SYSTEM - EQUIPMENTS

- particular surge atmospheric tanks to feed diesel oil

users (turbogenerators, diesel generators for process, diesel
generators for living quarters, fire water pumps, ),
Typical surge time to size these surge tanks :
for turbogenerator: 1 hour ,
for diesel generators for process: 2 hours,
for diesel generators for living quarters: 2 hours,
for fire water pumps: 24 hours.

- transfer diesel oil pumps:

between storage tank and intermediate tank,
between intermediate tank and particular surge tanks,
to particular users.

DGEP/SCR/ED/ECP

31

FUEL SYSTEM - DIESEL OIL SYSTEM - EXAMPLE

Supply
PC

Atmospheric
storage tank

Cartridge
filter and
coalescer

Atmospheric
intermediate
tank

T urbo
generator(s)

Supply

Filter coalescer
Offshore
high-demand:
80-200 m3/hr
low-demand
50-100 m3/hr
Road tankers
36 m3/hr

Atmospheric
storage tank

or centrifuge

Fire water pump(s)

Atmospheric
intermediate
tank

Diesel generator(s)
CO2 generator(s)

Figure 1 - Example of utility flow diagram for a diesel oil system.

DGEP/SCR/ED/ECP

Heater(s)

32

FUEL SYSTEM - DIESEL OIL SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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FUEL SYSTEM - DIESEL OIL SYSTEM - EXAMPLE

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FUEL SYSTEM - DIESEL OIL SYSTEM - EXAMPLE

DGEP/SCR/ED/ECP

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Sea Water and Cooling Water Systems - USERS

In oil and gas processing and conditioning plants it is

necessary to cool (water is the traditional fluid for cooling) :
- process stream, such as:
gas at compression discharge, at interstage compression, at
compression suction,
stabilized crude oil at discharge transport or transfer pump,
etc,

- equipment auxiliaries such as:

gas compression system,

- utilities equipment, such as:

DGEP/SCR/ED/ECP

main power generation,

air system compressors,
electrochlorination system,
diesel motor system,

36

Sea Water and Cooling Water Systems - CONDITIONS

To prevent excessive deposits or corrosion of heat

exchanger:
the inlet temperature of water in a heat exchanger is limited to 30C
(maximum maximorum = 35C),
the temperature increase of water in a heat exchanger is limited to
10C (maximum maximorum = 14C) but for sea water this value
must take account of local sea water characteristics and of
maximum skin temperature in the heat exchanger.

The minimum temperatures to which fluid can be cooled

are approximately 8 to 12C above water inlet temperature
in the heat exchanger. This minimum may be 3 to 5C for
cooling water/sea water heat exchanger when plate
exchangers are used (choice depends of economic
approach.

DGEP/SCR/ED/ECP

37

Sea Water and Cooling Water Systems - TYPES

In a once-through type:
- pumps take suction from a source of supply (sea, river,...),
and deliver the water to process units or to other users,
- after passing through cooling equipment (direct sea water
cooling), the hot cooling water is conducted to a point of
disposal to sea, river.

In a recirculated system:
-

the cooling-water system is composed of a recirculated

cooling water loop (secondary cooling medium) to remove
heat in process plants and before storage of final products,
- a once-through cooling-water system (primary cooling
medium) to remove heat in the recirculated cooling water
loop.

DGEP/SCR/ED/ECP

38

Sea Water and Cooling Water Systems - TYPES

In offshore:
- sea water circulated in a once-through system cool down the
recirculated cooling water of the closed loop of the cooling
system described further (sea water is in this recirculed type the
primary cooling medium).

In onshore two primary cooling medium can be used:

- air: when air is the primary cooling medium cooling water is cool
down in a cooling-tower. Pumps take suction from a coolingtower basin and deliver water to cooling equipment. After
passing through water users, the hot cooling water is
discharged through a pressure-return system to the top of the
cooling-tower,
- river water: when river water is used the conception of the
cooling system is similar to the offshore case.

DGEP/SCR/ED/ECP

39

Sea Water and Cooling Water Systems EQUIPMENTS

The main components of the sea water system are:
- pump inlet caissons, for drawing sea water from an
appropriate depth,
- sea water lift pumps, to provide a stable supply of sea
water at the appropriate pressure,
- marine growth inhibition and sea water filtration
packages for water quality control,
- sea water supply and return headers,
- an overboard dump caisson providing safe and
convenient disposal.

DGEP/SCR/ED/ECP

40

Sea Water and Cooling Water Systems EQUIPMENTS

The main components of the cooling system are:
- recirculation loop expansion drum,
- recirculating loop pumps,
- heat exchangers.

Hazardous and non-hazardous users shall be segregated

to prevent the possibility of hazardous substance
migration into non-hazardous areas/users.
- complete segregation of hazardous users from non-hazardous
users, a separate utility system serves each of the two user
categories,
- a single sea water lift system supplies non-hazardous users
and cools a closed circuit heat transfer system serving
hazardous users is a system intrinsically safe.

DGEP/SCR/ED/ECP

41

Sea Water and Cooling Water Systems - EXAMPLE

Back wash water

Sea water
heat
exchangers or
cooling water
system

Sea water
filter

PC

Back wash water

Overflow
Sea level

Sea water
desalting
system

Electrochlorination
package

Sea water
lift pump

Figure 3 - Example of simplified utility flow diagram for sea water system

DGEP/SCR/ED/ECP

42

PC

Water
injection
system

Sea Water and Cooling Water Systems - EXAMPLE

Cooling
water
expansion
drum

TC

Cooling
water
coolers
Cooling water supply manifold process
users and equipment auxiliaries

sw
sw

Cooling
water
make-up

Pumps

Figure 4 - Example of utility flow diagram for a cooling water system in a closed loop.

DGEP/SCR/ED/ECP

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P DC

Sea Water and Cooling Water Systems - EXAMPLE

DGEP/SCR/ED/ECP

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Sea Water and Cooling Water Systems - EXAMPLE

DGEP/SCR/ED/ECP

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Sea Water and Cooling Water Systems - EXAMPLE

DGEP/SCR/ED/ECP

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Sea Water and Cooling Water Systems - EXAMPLE

DGEP/SCR/ED/ECP

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HOT FLUID (OIL, WATER, ...) SYSTEMS - USERS

In oil and gas processing and conditioning plants it

is necessary to heat:
- heavy crude oils to favour its stabilisation, dehydration
and desalting,
- gas used to regenerate molecular sieves in gas or
condensate drying units,
- bottom stream in reboilers of depropanisers,
debutanisers and condensate stabiliser column, MDEA
reboilers,...

DGEP/SCR/ED/ECP

48

HOT FLUID (OIL, WATER, ...) SYSTEMS CONDITIONS

Pressurised heat water can be used in a recirculated
system to process heavy crude oils. In such case hot
water is heated until a temperature of around 180C
and allows to heat heavy crude oil until a temperature
of around 85C.
Pressurised hot oil system is used in gas processing
where elevated temperatures are required for the
process streams:
- 230 to 300C for gas used to regenerate molecular sieves,
- 100 to 200C for bottom stream in reboilers of
depropanisers, in reboilers of debutanisers, in reboilers of
condenser stabiliser.

DGEP/SCR/ED/ECP

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HOT FLUID (OIL, WATER, ...) SYSTEMS ALTERNATES

Direct and indirect fired heaters instead of hot fluid
recirculation type
- In all cases advantages and drawbacks of this system
must be compared with those of direct and indirect fired
heaters,
- Steam is not used in oil field or gas field plants. It is only
used in some LNG plants,

DGEP/SCR/ED/ECP

50

HOT FLUID (OIL, WATER, ...) SYSTEMS - HOT OIL

Hot oil is used in both liquid and vapour phases:

- in liquid, the fluid flows from the circulation pump to the
heater, then to the heat users, and back to the pump,
- in vapour phase applications, the fluid is vaporised in the
heater and condensed in the user, and the resulting
condensate flows back to the vaporiser.

DGEP/SCR/ED/ECP

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HOT FLUID (OIL, WATER, ...) SYSTEMS - HOT OIL

The types of oils used most commonly in the oilfield are:

- alkylated derivatives of benzene and polyphenyls. These liquid
phase fluids are used in the majority of applications up to
340C,
- aryl ethers. These are the most thermally stable fluids. An
eutectic mixture of diphenyl and diphenyl oxide (PD and DPO)
is stable up to 400C. Because DP and DPO boil at essentially
the same temperature, this mixture is often used in the vapour
phase,
- paraffins. These range from low-priced mineral oils to
synthetic isoparaffins. The maximum operating temperature is
300C. They are non-toxic and environmentally friendly,
especially compared to aromatics.

DGEP/SCR/ED/ECP

52

HOT FLUID (OIL, WATER, ...) SYSTEMS - HOT OIL

The advantage of hot oil include:

- low vapour pressure at ambient temperature,
- easy to handle,
- formulated for specific temperature range,

Their drawbacks are:

-

escaping vapours are often environmentally undesirable,

low heat-transfer properties,
ANSI Class 300 flanges are usually required,
when overheated the oils will degrade, oxidise if air is present,
and coke on the heater walls. Also they can be ignited,
- fluids that contain ethers are hygroscopic and must be kept
dry.

DGEP/SCR/ED/ECP

53

HOT FLUID (OIL, WATER, ...) SYSTEMS EQUIPMENTS

Equipment considerations:
- heater:
heater (furnace),
waste heat recovery unit (WHRU) linked to a gas turbine or
other hot flue-gas producer,
The heat source may be of several
heat exchanger.

types: electric resistance, fired heater,

hot oil air cooler,
or waste heat recovery unit (WHRU)
make better use of available energy but
hot oil expansion drum,
they should be selected after due
heat exchangers (consumers), consideration of their limitations
(operational flexibility in particular).
pumps,

- oil storage and drainage.

DGEP/SCR/ED/ECP

54

HOT FLUID (OIL, WATER, ...) SYSTEMS - EXAMPLE

PC

Hot oil
expansion
drum

WHRU

Hot oil
furnaces

Hot oil air

cooler

TC
FC

Hot oil
pumps

From hot
oil storage

From hot
oil
drainage

Hot oil
filters

By
pass

FC

Gas turbine
exhaust
TC

TC

To hot oil
storage

FG

Hot oil drain drum

and pump

Figure 7 - Example of utility flow diagram for a hot oil system.

DGEP/SCR/ED/ECP

55

Hot oil supply manifold

process users

HOT FLUID (OIL, WATER, ...) SYSTEMS - EXAMPLE

With steam
at 170C (8 barg),
latent heat
488 kcal/kg
- Stabilisation
reboiler column
12.4.106 kcal/h
(14.5 MW)
=> 25 500 kg/h
of steam
- Amine
regeneration
reboiler
13.6. 106 kcal/h
(15.8 MW)
=> 28 000 kg/h
of steam
DGEP/SCR/ED/ECP

56

HOT FLUID (OIL, WATER, ...) SYSTEMS - EXAMPLE

DGEP/SCR/ED/ECP

57

HOT FLUID (OIL, WATER, ...) SYSTEMS - EXAMPLE

DGEP/SCR/ED/ECP

58

ELECTRIC POWER SYSTEM - GENERAL

The source of electrical energy for oil an gas

processing field plant must be determined:
- if purchased power is to be utilised, the voltage level and
quantity of power available must be known,
- when commonly power is generated in oil and gas
processing field plant, the size of generators should be
established in accordance with the estimated required
operating power determined with the estimated electric
energy balance and the philosophy on spare generation.

DGEP/SCR/ED/ECP

59

ELECTRIC POWER SYSTEM - GENERAL

Once the over-all aspects of the oil and gas processing

field plant power system are established, decisions are
needed for:
-

voltage levels of various users,

motor characteristics,
distribution voltage in the plant,
substation capacity and location to suit loads,
hazardous and nonhazardous area designations,
switch, switchgear, motor starter, and circuit-breaker
specifications,
- shelters and enclosures for electrical gear or weatherproof or
explosionproof gear in place of enclosures,
- area lighting requirements.

DGEP/SCR/ED/ECP

60

ELECTRIC POWER SYSTEM - GENERAL

The choice of rotating machines which are

electrically driven must be done after a detailed study
of each machine including the cost of equipment, the
weight, the maintenance cost, the deck area, and
overall safety of the plant.
The choice of heaters which are electrically operated
(e.g. glycol reboiler, ) must be done taking first
account of the overall safety of the plant.

DGEP/SCR/ED/ECP

61

ELECTRIC POWER SYSTEM - USERS

Usual users:
- in oil treatment unit:

booster pumps (for oil expedition),

main oil pumps (for oil expedition or storage facilities),
condensate pumps,
associated gas compressors,
desalters,

- in gas treatment unit:

glycol pumps,
refrigeration loop compressor if any,
pipeline or gas lift or reservoir reinjection compressors,

DGEP/SCR/ED/ECP

62

ELECTRIC POWER SYSTEM - USERS

- in water injection unit:

- in cooling water unit

(cooling loop in any):

winning pumps,
sea water service pumps,
injection booster pumps,
vacuum pumps if any,
chemical injection pumps,
electro-chlorinator,
air blower compressor;

cooling loop
recirculating pumps,
cooling system filling
pump;

- air compressor:
air compressor,
air dryer;

- in water treatment unit:

DGEP/SCR/ED/ECP

recovered oil pumps,

oily water pumps,
submersed pumps,
flotation units if any,

- fire protection:
jockey pumps;

63

ELECTRIC POWER SYSTEM - USERS

- miscellaneous:
workshops,
heaters,
start-up motors of gas
turbines,
plant lighting,
heating-ventilation air
conditioning (HVAC),
heat trace,
instrumentation,
living quarters,
deck handling (Crane, ),

DGEP/SCR/ED/ECP

64

and do not forget

rotating machine
auxiliaries (1% to 4%
of shaft power)
A contingency value of
25 % must be added to
the determinated total
electric power for
feasibility studies, 20
% for preproject
studies.

ELECTRIC POWER SYSTEM - EXAMPLE

Electrical process load breakdown
Water injection (700)
Offloading (300)
Others utilities (900)
Gas compression (500)
Oil treatment (300)
Margin
Floater
Others
Gas treatment (600)
FG, AI, Chemicals (800)
Cooling medium (940)
Electricity (980)
Heating medium (850)
Produced water treatment (400)

36.6%
19.7%
8.8%
8.4%
6.5%
4.5%
4.4%
3.6%
2.4%
1.6%
1.6%
1.5%
0.3%
0.1%

Others
Heating medium (850)
Electricity (980)
Cooling medium (940)
FG, AI, Chemicals (800)
Others utilities (900)
Water injection (700)

DGEP/SCR/ED/ECP

With
offloading

36%

Without
offloading

47%

37%

1%
2%
2%
11%

9%
2%

65

2% 2%

0.3%

49%

ELECTRIC POWER SYSTEM - EXAMPLE

Process objectives:
- electrical process load with offloading: 50 000 kW,
- electrical process load without offloading: 40 000 kW,

Basis for design:

- 3 x 26 MW ISO,
- 1 spare without offloading, 0 spare with offloading,

Electrical generation alternatives:

- aeroderivative versus Heavy Duty turbines.
PARAMETERS
Cost
Maintenance
Reliability
Weight
Efficiency
Gas supply pressure

DGEP/SCR/ED/ECP

AERODERIVATIVE

HEAVY DUTY

++
+++
+
+
30 35 %
30-35 bar g minimum

+
+
++
+++
20-25%
16 bar g minimum

66

PROJECT IMPACT - EXAMPLE

DGEP/SCR/ED/ECP

67

PROJECT IMPACT - EXAMPLE

Heating:
40 MW
Cooling:
90 MW
Electricity:
50 MW
Fuel gas:
1 000 000 Sm3/d

DGEP/SCR/ED/ECP

68

PROJECT IMPACT - EXAMPLE

FPSO total load [91 264 tons (material) + 301 279 tons (content)]

300000

Content
Material

250000

Weight (tons)

200000

150000

100000
295607

5672
50000
30667

10468
0

DGEP/SCR/ED/ECP

69

50129

PROJECT IMPACT - EXAMPLE

Topsides weight [30 667 tons (material) + 5 672 tons (content)]

12 000

10 000
WEIGHT (tons)

Structure 45.4%
Equipments 31.0%
Piping 20.3%
Electricity 1.8%
Instrumentation 0.7%
Paint 0.4%
Others 0.4%

14 000

Content
Material
3 416

8 000

6 000

9 508

4 000

6 219

2 000

DGEP/SCR/ED/ECP

13 909

2 256

117

138

227

70

549

PROJECT IMPACT - EXAMPLE

Equipments weight [9 508 tons (material) + 3416 tons (content)]
1 222
3 000

Breakdown material
Electricity (980) 25.5%
Water injection (700) 19.5%
Others utilities (900) 14.5%
Gas compression (500) 13.4%
Oil (300) 12.9%
FG, AI, Chemicals (800) 4.4%
Produced water (400) 4.2%
Heating medium (950) 2.9%
Gas treatment (600) 0.9%
Flare (200) 0.8%
cooling medium (940) 0.8%
Others 0.5%

2 500

WEIGHT (tons)

2 000

1 500

Content
Material
1 857

Utilities: 67 %(*)
Process: 33 %
1 270

1 000
415
272

500
43

88

73

75

(*) 50% if water lifting and injection is not included

DGEP/SCR/ED/ECP

2 422

71

397

1 374