Group member :

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United Arab Emirates UniversityCollege of
EngineeringChemical petroleum Engineering
Design of Oil Production Surface Facilities

• Group member
• Mansoor Sulaiman AlBalooshi
  200308910
• Saleh Salem AlAmeri
  200235706
• Ahmed Mohamed Obaid
  200209570
• Advisor Dr Mohamed Al Nakoua

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Acknowledgments

• We would like to thank
• Dr. Mohammed Al Nakoua - our advisor.
• Dr. Ahmed Gaouda - our coordinator.

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Contents

• Objective.
• Introduction.
• Plant Design.
• Material Balance.
• Separators Design.
• Gas Sweetening Column Design.
• Gas Dehydration Column Design.
• Conclusions.

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Objective

• Design a plant for separation and treatment of
  petroleum fluids.

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Introduction

• Data
• Dubai Petroleum Company.
• MARGAM field which is an onshore field.
• It is a gas field.

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Plant Design
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Material Balance

• Material balance was carried out using HYSYS
  program on
• First separator.
• Second separator.
• Mixing point.

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Material Balance for first separator

• Flow rate of natural gas
• 125 MMSCFD
• 6241.753 Kgmole/hr

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Component Stream3 (kgmole/hr) Stream2 Kgmole/hr Stream4 Kgmole/hr
H2O 0.53 1.515 2328.531
N2 6.5191 18.435 H.C. 2.747
CO2 16.1001 19.446 -
C1 1001.1575 2385.505 -
C2 109.5017 66.923 -
C3 86.5833 22.476 -
iC4 26.743 3.788 -
C4 40.3151 4.546 -
iC5 20.5423 1.263 -
C5 16.0631 0.758 -
C6 17.8126 0.253 -
C7 43.7242 0.505 -
Total 1385.592 2525.413 2331.28
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Component Stream5 (kgmole/hr) Stream6 Kgmole/hr Stream7 Kgmole/hr
H2O - 0.5299 0.0001
N2 - - 6.5191
CO2 16.1 - -
C1 1001.1575 - -
C2 6.101 - 103.4007
C3 - - 86.5833
iC4 - - 26.743
C4 - - 40.3151
iC5 - - 20.5423
C5 - - 16.0631
C6 - - 17.8126
C7 - - 43.7242
Total 1023.359 0.5299 361.7035
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Component Stream2 (kgmole/hr) stream5 (kgmole/hr) Stream8 (kgmole/hr)
H2o 1.515 - 1.515
N2 18.434 - 18.434
CO2 19.446 16.1 35.546
C1 2385.505 1001.1575 3386.6625
C2 66.923 6.101 73.024
C3 22.476 - 22.476
iC4 3.788 - 3.788
C4 4.546 - 4.546
iC5 1.263 - 1.263
C5 0.758 - 0.758
C6 0.253 - 0.253
C7 0.505 - 0.505
Total 2525.413 1023.359 3548.772
Stream2
Stream8
Stream5
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Separators Design

• Horizontal separator
• Two separators were designed

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Procedure for sizing separator

• Calculate CD
• Vt 0.0119 (?L ?g/?g) dm/CD
• Re 0.0049 ?g dmVt/ µg
• CD 24/Re 3/(Re)0.5 0.34
• First assumption for CD is 0.34

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Procedure for sizing separator (continue)

• Calculating Z
• Tpc 170.5307.3 S.G
• Ppc709.6-58.7 S.G
• PPr P/ Ppc
• Tpr T/ Tpc

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Procedure for sizing separator (continue)
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Procedure for sizing separator (continue)

• Gas Capacity Constraint
• dLeff 420 TZ(Qg/P) (?L ?g/?g)
  (CD/dm)0.5

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Procedure for sizing separator (continue)

• liquid Capacity Constraint and seam to seam
  length
• d2Leff tr QL /0.7
• Lss Leff d/12 (for gas capacity)
• Lss 4/3 Leff (for liquid capacity)

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Procedure for sizing separator (continue)
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Data
T,oR P,psia Qg,MMscfd QL , bbl/d µg, Cp tr,min dm,micron
560 1002 125 3000 0.013 2 100
?L 62.43 lbm/ft3
?g2.7((S.Gg)P/TZ) 4.34 lbm/ft3
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Sizing first separator

• By iteration CD is found to be 1.004
• Z 0.78

d,in Gas Leff,ft Liquid Leff,ft Lss (gas),ft Lss(liquid),ft 12 Lss/d
24 26.616 14.881 28.616 35.489 17.744
30 21.293 9.524 23.793 28.391 11.356
36 17.744 6.614 20.744 23.659 7.886
42 15.209 4.859 18.709 20.279 5.794
48 13.308 3.72 17.308 17.744 4.436
A 48-in diameter 18-ft length separator provides
about two minutes retention time
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Sizing second separator

• Data

P,psia T,oR µg,Cp (S.G)g QL,bbl/d Qg,MMscfd dm,in tr,min
480 510 0.01 0.9 1.5 0.7 100 3
Z 0.81 ?L 62.43 lbm/ft3 ?g 2.824 lbm/ft3
CD 1.003
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Sizing second separator (continue)
d,in Gas Leff,ft Liquid Leff,ft Lss (gas),ft Lss(liquid),ft 12 Lss/d
36 0.23 0.011 6 0.306 3
A 24-in (3-ft) diameter 6-ft length separator
provides about three minutes retention time
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Reason for sweetening Natural gas

• To meet sales specifications.
• To prevent corrosion.
• To allow less costly metallurgy.
• To remove toxicity hazards. (H2S).

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Gas sweetening column design

• Monoethanolamine (MEA) as a reactive solvent.
• Amine enters the top of the sweetening tower.
• The acid gas enters from the bottom of the tower.
• A number of trays which in our project equal to
  twenty trays.

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Gas sweetening column design

• The amine and the acid contacted and the amine
  absorb CO2 by chemical reaction.
• The loaded Amine (rich amine) with CO2 exit from
  the bottom of the tower.
• 25 of Amine can be regenerated after sweetening

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Gas sweetening column design

• Circulation rate, gpm
• (K)(MMscfd)(Mole of acid gas)
• (2.05)(3)(1.0) 6.15 gpm

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Gas sweetening column design

• For the diameter we have flow 3MMscfd and the
  pressure is 465psig.
• I. D. 12 in.

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Main reasons for gas dehydration

• Hydrate formation can plug valves, fittings or
  even pipelines.
• Corrosion, especially when CO2 and/or H2S are
  also present.
• Water will condense in the pipelines causing slug
  flow and possible erosions.

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Gas dehydration column design

• Glycol injection method.
• Triethelyne glycol (TEG).
• The TEG enters from the top of the dehydrator.
• The wet gas enters from the bottom.
• The dehydrators internals consists of a number
  of trays which are twenty trays.

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Gas dehydration column design

• The glycol absorbs the water vapor form the wet
  gas.
• The dry gas goes out from the top of the
  dehydrator.
• The wet glycol leaves the dehydrator from the
  bottom.
• 99 of wet glycol can be regenerated after
  dehydration.

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Gas dehydration column design

• For the diameter we have flow 3MMscfd and the
  pressure is 480psia.
• I. D. 2 ft

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Conclusions

• Data was collected from Dubai Petroleum Company
• Two separators were designed for the system
• Gas dehydration and sweetening columns were also
  designed.
• The final plant products were sweet methane gas,
  NGL, Water, Carbon dioxide
• HYSYS was found a powerful software