2/4/2013

INTERNSHIP REPORT Pakistan Pertroleum Limited

Pakistan Petroleum Limited

Prepared by: Sadia Urooj Submitted to: Dr. Shujjat Ahmed, Manager Process Engineering (MPrE).

University of Karachi

ACKNOWLEDGEMENT

All praise unto Almighty Allah, the Lord of all worlds, who endowed me with the ability to complete successfully this period as internship. My Lord, I have never been unblessed in my prayer to you. I am extremely thankful for the co-operation and help provided byDr. Shujjat Ahmed (MPrE), Mr. Farooq Azam Shah (DCE Pr), Mr. Imran Bukhari (EPr), Mr. Athar (TrE Chem) for spending their valuable time and responding to my queries and giving me an insight how an organization is run, what are the important principles of a working environment, how projects are designed, their implementation and what are the softwares used in executing these tasks. I feel myself an opportunist after served the high tech environment in PPL which shall be a guideline in my future career. Last but not the least, I am thankful to all those who always have guided me at their best.

Sadia Urooj Student, Chemical Engineering (Batch 2009) University of Karachi

TABLE OF CONTENTS

S.No 1.

DESCRIPTION

Page# 5

Introduction 1.1. General (Oil & Gas Industry Work Flow) 1.2. Plant Operations 1.3. PPL Process Engineering Department major scope: - Technical Services - Process Design

2.

Introduction With Process Engineering 2.1. Fundamentals of Process Design 2.2. Standards and Codes Frequently used in Process Design & Their Application 2.3. Introduction with Unit Operation & Unit Processes in PPL Plants

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3.

Preparation Of Requirements

Process

Design

Documents

&

Their

Standard

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3.1. Schematic 3.2. PFDs 3.3. H&MB 3.4. P & IDs 3.5. Plot Plan 3.6. Process Simulation (HYSYS)
4.

Process Design Calculation Of Pipelines System & Major Process Units 4.1. Introduction with Transient Flow Regimes 4.2. Hydraulic Calculation of Process Piping 4.3. Separators (2-Phase, 3-Phase, Knock Out, Scrubbers etc.) 4.4. Heat Exchangers (S&T, Air Coolers etc.) 4.5. Towers (De-Ethanizer, De-Butanizer, Stripper) 4.6. Pumps (Centrifugal, Reciprocating etc.) 4.7. Compressors (Centrifugal, Reciprocating etc.) 4.8. Storage (LPG, NGL, Diesel, Water etc.) Conclusion References Annexures

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42 43 44 3

ANNEXURES

Annexure A: Electrical standards and approved codes of practice Annexure B: Block Flow Process Diagram Annexure C: Block Flow Plant Diagram Annexure D: Process Flow Diagrams (PFDs) Annexure E: Piping and Instrumentation Diagram (P&IDs) Annexure F: Plot Plan Annexure G: Separator Sizing Annexure H: Compressor Design

INTRODUCTION

Pakistan Petroleum Limited

Pakistan Petroleum Limited invariably known as PPL is the pioneer in the gas production of the country, contributing about one fourth of total gas supplies, besides producing crude oil, condensate and LPG. Pakistan Petroleum Limited has been in the business of exploration and production since 1950 with the establishment of a public limited company through major shareholding of a Britain based company (Burmah Oil Company). Presently PPL's share in the country's total natural gas production stands at around 24 percent. The company operates the largest gas field at Sui and five others at Kandhkot, Hala, Chachar, Adhi, and Mazarani. It holds working interest in 12 partner operated fields including Qadirpur, Sawan, Nashpa, Latif etc. PPL-operated fields produce an average of one bcfd which is sold to the company's main clients: Wapda, SSGC and SNGPL. The exploration portfolio of the company consists of 35 exploration blocks including offshore block Indus-G. Pakistan Petroleum Limited is the operator in 19 of them, while it has working interest in 15 of them as well. These numbers also include the exploration license in Yemen, which is a joint venture between PPL, OMV and Yemen General Corporation for Oil and Gas. However, due to security issues, progress in this regard has been halted completely in recent times.

1.1. General (Gas Industry Work Flow)

Oil and gas field production and processing operations are primarily defined by the following activities: Exploration and production (E&P) ; Processing; Storage and transport; and
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Wastewater. EXPLORATION AND PRODUCTION

1.1.1.

The oil and gas field production and processing operations begin with exploration to locate new sources of crude oil and natural gas. Seismic and other geophysical methods are used to locate subterranean formations that signal the potential presence of oil and gas reservoirs. When potential sources are located, wells are drilled to confirm the presence of oil or gas and to determine whether the reserves are economically sufficient to support production. Once a well has been completed and is producing crude oil or natural gas, an arrangement of high-pressure valves termed a "Christmas tree" is installed to control production. As the well ages, an artificial lift device may be needed to help bring product to the well surface. 1.1.2. PROCESSING

1.1.2.1.

CHEMICAL INJECTION SKIDS

Chemical agents employed in field processing include drilling fluid additives, methanol injection for reservoir stimulation, glycol injection for hydrate inhibition, produced water treatment chemicals, foam and corrosion inhibitors, de-emulsifiers, desalting chemicals and drag reduction agents (DRAs). Chemicals are frequently administered by way of chemical injection skids.

1.1.2.2.

WELL STREAM SEPARATION

The first step in processing the well stream is to separate the crude oil, natural gas and water phases into separate streams. 1.1.2.3. FIELD STORAGE TANKS

Crude oil, natural gas liquids (NGLs) and water are stored in oil and gas fields. Field storage consists of smaller vessels associated with oil, gas and water processing. 1.1.2.4. WATER PROCESSING

Water collected from process operations contains hydrocarbon concentrations too high for safe discharge thus it requires treatment. Suspended hydrocarbon droplets in water also hinder well-injection. 1.1.2.5. CRUDE DEHYDRATION, DESALTING & STABILIZATION

Separated crude may contain up to 15% water which exists in an emulsified form. Deemulsification processes are accomplished using chemical agents and heat. Crude desalting removes both salt and the residual free water. By removing dissolved gases and hydrogen sulfide, crude stabilization and sweetening processes diminish safety and corrosion problems. 1.1.2.6. VAPOR RECOVERY UNIT

If allowed to escape into the atmosphere, hydrocarbon vapors diminish income through loss of hydrocarbon volume and create fire hazards and pollution problems. A Vapor Recovery Unit (VRU) collects vapors from storage and loading facilities, reliquefies the vapors and returns the liquid hydrocarbons back to storage. Methods to recover vapors include absorption, condensation, adsorption and simple cooling. 1.1.2.7. GAS DEHYDRATION

Natural gas dehydration removes hydrates which can grow as crystals and plug lines and retard the flow of gaseous hydrocarbon streams. Dehydration also reduces corrosion, eliminates foaming, and prevents problems with catalysts downstream. Natural gas is dehydrated according to the customers specifications for maximum water content.
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1.1.2.8.

SOUR GAS TREATMENT

Pipeline specifications require removal of the harmful acid gases carbon dioxide (CO 2) and hydrogen sulfide (H2S). H2S is highly toxic and corrosive to carbon steels. CO2 is also corrosive and reduces a gass BTU value. Gas sweetening processes remove these acid gases and make natural gas marketable and suitable for transportation. 1.1.2.9. NGL RECOVERY

Separating the hydrocarbons and fluids from pure natural gas produces pipeline quality dry natural gas. The two principle techniques for removing Natural Gas Liquids (NGLs) are the absorption and the cryogenic expander method. 1.1.2.10. PUMPS & COMPRESSORS

Pumps are used throughout field operations for moving drilling fluids, crude oil and produced water. Compressors increase the pressure of natural gas to facilitate pipeline transport. 1.1.2.11. LIQUID AND GAS FLOW

The flow of process liquids and natural gas in field operations must be monitored for safety and efficiency. 1.1.2.12. TANK BLANKETING

Nitrogen is commonly used as a tank blanketing gas in order to prevent ignition of flammable liquids, provide an oxygen and moisture barrier, inhibit vapor loss and maintain a tanks pressure balance. 1.1.2.13. FLARE STACKS & HEADERS

Hydrocarbon gases are often flared in a high-temperature oxidation process which burns combustible components of waste. 1.1.3. STORAGE AND TRANSPORT

Storage tanks are used to store crude oil, liquefied natural gas (LNG), water or brine, process condensate, as well as other materials used or generated during the production of oil and natural gas. Crude oil is transported from production operations to refineries by tank
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trucks, rail cars, tankers, barges, and pipelines. Loading methods include splash loading, submerged pipe fill, and bottom loading. Natural gas is transported by pipeline. Pipeline pigging operations are conducted to assist in product transfer and product separation, as well as for maintenance activities. A pig is a physical device which varies in size and shape and can be made of a variety of materials such as plastic, urethane foams, and rubber. Pigs can be solid, inflatable, foam, or made of a viscous gel. The specific design of a particular pig depends upon the pipeline as well as the purpose of the pigging operation. Three types of pigging operations occur in pipelines at oil and gas field production and processing facilities: product transfer, product separation, and maintenance. Pigging following product transfer is used to remove residual product from the pipeline after loading occurs. Pigs can also be used for product separation to transport more than one product, such as oil, gas, or condensate as well as for maintenance activities such as pipeline cleaning, gauging, or dewatering. During pigging operations, a pig is inserted into the pipeline and is forced through the pipeline by a compressed gas, such as nitrogen. When the pig gets to the end of the line, it is trapped in a receiver. The gas is then bled off from behind the pig. Depending on the specific pigging operation, waste removed from the pipeline may also be an issue. 1.1.4. WASTEWATER

During oil and gas field production and processing operations, wastewater is generated from processes such as product separation and glycol dehydration. The wastewater may be treated on-site or it may be forwarded to an approved wastewater treatment facility. Many types of units are used to treat, store, and transfer wastewater on-site. Some of these units include sumps, pits, storage tanks, brine tanks, and oil/water separators which may be in primary, secondary or tertiary treatment service.

1.2. Plant Operations

Operation is a complex of activities performed by the operating staff to ensure safe and reliable operation of the plant equipment.

Plant operation has certain objectives.

Specifications: To meet the sales specifications. Capacity: Run at the designed flow rates. Flexibility: If operating ranges change, it can operate yet. Regulations: By-products specifications should be met. All effluents must meet the
environmental conditions based upon NEQS.

Safety system: Overall Occupational Health and Safety (OHSAS).

There are three types of plant operations, normal operations, shutdown and start up, and trouble-shooting. NORMAL OPERATION Its based on SOPs. Standard operating procedures should cover three main areas of operation. First is the safety considerations associated with the process. The operator must understand the process flow sheet and have a mental picture of how the plant is structured and how it operates. He must know where the pressure relief valves and rupture disks are located and where the releases will go in the event their operation is triggered by an upset in the process. The second element that needs to be covered in written standard operating procedures is a description of the control system. The third element in standard operating procedures involves specifying the standard operating conditions. SHUTDOWN AND START UP As takeoff and landing are most hazardous operations for an aircraft so in a process plant the hazard is greater during start-up and shut-down. Column Startup and Shutdown A column startup usually consists of the following steps: 1. Commissioning 2.Pressure-up 3.Column Heating (and/or cooling) 4.Introduction of feed
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5. Introducing heating and cooling sources 6. Bringing column to desired operating conditions Similarly, column shutdown usually consists of the following steps: 1. Reducing column rates 2. Shutting down heating and cooling sources 3. Stopping feed 4. Draining liquids 5. Cooling (or heating) the column 6. Bringing the column to atmospheric pressure 7. Eliminating undesirable materials 8. Preparing for opening to atmosphere Other activities required for carrying out a proper startup or shutdowns include: Preparation of operating, startup, shutdown (normal and emergency) and maintenance procedures and checklists for each phase Selection and training of startup/shutdown team Planning and coordinating all activities, developing individual tasks and objectives, etc Securing any raw materials, catalysts, equipment, and spare parts required.

TROUBLE-SHOOTING Trouble-shooting is equipment based. Trouble-shooting is more in rotary equipments than stationary equipments. In trouble-shooting, we do root cause analysis. Trouble-Shooting Checklist for Amine Systems Dirty Amine Cyanides Amine color and solids concentration Inadequate filtering Corrosive amines Regenerator feed temperature too high
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High velocities Stress cracking

Reboiler corrosion Corrosion inhibitor Condensate backup in channel head Regenerator reflux rate too low Superheated reboiler steam

Reclaimer operation High S2O3 levels Soda ash addition rate Diluent water rate Tubes not submerged in liquid

Energy reduction Minimize CO2 recovery Cut amine circulation Reduce reboiler steam

Foaming in scrubbers High N2 in refinery effluent Scrubber pressure drop Dirty amine Excessive concentrations of silicone or inhibitor Charcoal filter Condensing hydrocarbons Extraneous surfactants Plugged level control traps Liquid-liquid scrubbers

Loss in amine strength Amine cooler leaking

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Reboiler or reclaimer leaking Condensate make-up or valve open Test with tracer chemical

Poor sweetening Leaking cross exchanger Regenerator reflux rate too low Amine degraded COS in treated propylene

1.3. PPL Process Engineering Department Major Scope

1.3.1.

TECHNICAL SERVICES

As a process engineer the overall objective is to ensure optimum running of theprocessing units in terms of capacity utilization, energy efficiency, equipment life, to provide timely assistance to operational problems, production planning, economic operating modes and quality control. Process simulation techniques are used for optimizing and troubleshooting the process of the plant through one of the major simulation tool HYSYS. Designing, evaluation and modifications for the plants to ease the operation and optimize the performance requiring good knowledge of hydraulic calculations. Updating daily plant monitoring sheet and wellness report of the department. 1.3.2. PROCESS DESIGN

As a process engineer , the design of any process contribute a great deal in the development of industrial output and satisfactory as well as safe operation of the plant. The process engineering department of PPL contribute a lot in designing , increasing production, assisting new projects , meeting the standards , gathering data from standard procedure and coming up with adequate and economical plant design.

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INTRODUCTION WITH PROCESS ENGINEERING

2.1. Fundamentals of Process Design

In business a process is any sequence of events or actions that transforms inputs into outputs. For example, a car business takes in metal and labor and transforms it into cars through a process of car manufacture. Processes are designed so as to make most efficient use of resources, including time, labor and capital. 2.2.1. DESIGN BRIEF

The first stage in process design is the design brief. The design brief is usually achieved through extensive consultation among the clients who will be using the process, and whoever will be implementing the process. The design brief includes information about the requirements, specifications, costs, schedule and objectives of the process. 2.2.2. SPECIFICATION

Included within the design brief is the specification. The specification is a detailed description of the properties that the process needs to possess. The specification will establish in detail the criteria by which the success or failure of the design of the process will be judged. 2.2.3. CONCEPT

The concept is a high-level description of how the process will function. The concept stage of process design involves a great deal of abstraction. Complex subsystems of the process are presented as "black boxes" with certain inputs and certain outputs. The goal of the concept stage of process design is simply to ensure that the design as specified is feasible, and to identify any major problems with implementing the specified process design. 2.2.4. DETAILS

After the concept has been established, the subsystems can be removed from their black boxes and the work of designing the process at a detailed level can begin. This part of designing processes generally takes the longest, as consideration has to be made of all the detailed elements of the process subsystems.

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2.2.5.

TESTING

As the process is implemented, each subsystem has to be tested to ensure it works properly. Once all the subsystems of the process have been implemented, testing has to happen to ensure that everything works as required by the specification. If things do not work as required by the specification, then they have to be altered so they do. 2.2.6. ONGOING MONITORING

Even once the process is set up and operational, there is still scope for ongoing monitoring and improvement of the system. Systems like Kaizen offer a means to extend the process design process over the entire lifetime of the system, ensuring that the process is constantly being developed and inefficiencies are removed.

2.2. STANDARDS AND CODES

STANDARDS
A technical standard is an established norm or requirement. It is usually a formal document that establishes uniform engineering or technical criteria, methods, processes and practices.

CODES
A code is a set of rules and specifications for the correct methods and materials used in a certain product, building or process. Codes can be approved by local, state or federal governments and can carry the force of law. The main purpose of codes is to protect the public by setting up the minimum acceptable level of safety for buildings, products and processes.

2.2.1.

AMERICAN PETROLEUM INSTITUTE (API)

The American Petroleum Institute (API) maintains more than 500 documents that apply to many segments of the oil and gas industry - from drill bits to environmental protection. API standards advocate proven, sound engineering and operating practices and safe, interchangeable equipment and materials.

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API standards include manuals, standards, specifications, recommended practices, bulletins, guidelines and technical reports.

2.2.2.

ASTM INTERNATIONAL

ASTM International is comprised of more than 132 technical standards writing committees and publishes over 9,100 standard specifications, tests, practices, guides, and definitions relating to materials, products, systems, and services. Topics range from chemical products and fossil fuels to forensic sciences and medical devices.

2.2.3.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO, the International Organization for Standardization, is a nonprofit organization that develops and publishes standards of virtually every possible sort, ranging from standards for information technology to fluid dynamics and nuclear energy. Headquartered in Geneva, Switzerland, ISO is composed of 162 members, each one the sole representative for their home country

2.2.4.

NFPA STANDARDS AND CODES

NFPA develops, publishes, and disseminates more than 300 consensus codes and standards intended to minimize the possibility and effects of fire and other risks. Virtually every building, process, service, design, and installation in society today is affected by NFPA documents.

2.2.5.

OSHA STANDARDS

The Occupational Safety and Health Administration (OSHA) regulates worker safety in the United States and its territories. Health and safety standards are contained in Title 29 of the Code of Federal Regulations (29 CFR), and are available online. In the OSHA CFR, there are several different sections (also called parts) of safety and health standards (also called regulations) applicable to the various types of workplaces regulated by this agency. There are OSHA standards (Part 1903) regulating OSHA inspections, citations, and penalties for all affected workplaces, as well as specific standards for reporting and recording OSHArecordable injuries and illnesses(Part 1904) that apply to all affected employers who do not fall into the exemptions for size or low-risk industries (although they must still comply with all other applicable OSHA regulations).
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2.2.6.

ELECTRICAL STANDARDS AND APPROVED CODES OF PRACTICE

There are some commonly used electrical standards and approved codes of practice shown in annexure. Additional standards and codes of practice would generally be needed to satisfy a specific application - it is the responsibility of the specified to select and apply these. You should ensure that the standard you use is the current one. The standards are organized into a number of topic areas and are ordered with the lowest number at the top of each table: Electrical and Power Electrical Appliances Electromagnetic Compatibility Flammable Atmospheres Machinery

2.3. Introduction with Unit Operation & Unit Operation in PPL Plants
The company operates the largest gas field at Sui and five others at Kandhkot, Hala, Chachar, Adhi, and Mazarani. It holds working interest in 12 partner operated fields including Qadirpur, Sawan, Nashpa, Latif etc. PPL-operated fields produce an average of one bcfd which is sold to the company's main clients: Wapda, SSGC and SNGPL.

2.3.1. SUI GAS FIELD (PPL SHARE 100%)

Since its discovery in 1952, the Sui Gas Field remains an important source of gas supply,meeting substantial part of gas demand of the country. Reservoirs in SUI are SUL, SML, HRL, Pab formation. SUL has no H2S, less CO2 so it undergoes dehydration only. Pab has a lot of H2S and CO2. H2S is upto 1000-1500 ppm. CO2 is maximum 7 mole%. As per sales gas requirement, H2S should be till 4 ppm and CO2 should be 3 mole% so it undergoes gas sweetening as well. SUI Plant is divided into three parts.
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SUI Compression Station HRL (small plant ) Capacity: 30 MMscfd SCFGCS (large plant ) Capacity: 900-950 MMscfd

SUI Purification Plant Capacity: 900-950 MMscfd

SUI Dehydration Plant Capacity: 200-300 MMscfd

2.3.2. KANDHKOT GAS FIELD (PPL SHARE 100%)

Gas from Kandhkot Field is mainly supplied to WAPDA and SNGPL for use at Guddu Thermal Power Station. A nominal quantity of gas is also supplied to SSGCL for Kandhkot Town. The unit operations at Kandhkot include compression and dehydration at Compression Station and Dehydration Plant.

2.3.3. ADHI FIELD (PPL SHARE 39%) PPL / OGDCL / POL JOINT VENTURE
Adhi has 3 plants. Plant 1 called LPG/NGL recovery plant was established in 1991. Plant 2 called EPL (Early Production Liquid) was established in 2006 and plant 3 will be established in 2014. Plant 1 and 2 requires no sweetening. Thus, plant 1 which is the main plant undergoes gas dehydration only and recovers LPG/NGL and plant 2 has a capacity of 5000 MMscfd. A total of eleven wells are in production at Adhi. Two wells are producing crude oil from Sakesar formation and the remaining are Tobra / Khewra wells producing oil, NGL and gas. LPG is also extracted from the Plant feed and sold to customers.

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2.3.4. MAZARANI GAS FIELD (PPL SHARE 87.5%) PPL / GHPL JOINT VENTURE
Mazarani gas field comprises of Gas Processing Plant and an 8 dia. 75 Km long gas transmission pipeline for injection of Mazarani gas into SSGCL's Indus Right bank transmission system. A total of four wells have been drilled to-date in Mazarani Field. Out of these four wells, Well Maz-1 was plugged and abandoned whileMaz-2(L), Maz-3(L) and Maz-4(L) have been completed in Laki formation and are in production. The unit operations and unit processes at Mazarani include Gas compression Amine unit Dehydration

2.3.5. CHACHAR GAS FIELD (PPL SHARE 75%) PPL / GHPL JOINT VENTURE
The field is in the East of Kandhkot Gas Field.A total of four wells have been drilled in Chachar Field, of which Chachar 1 and 2 are in normal operation and Chachar-4 is intermittently in operation due to water loading, while Chachar-3 is completely shut-in due to high water production.Cathodic Protection System has been installed and commissioned at Chachar-1, 2, 3 and 4 wells. The unit operations and unit processes at Chachar include Gas compression Amine unit Dehydration

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2.3.6. HALA GAS FIELD (PPL SHARE 65%) MGCL / PPL JOINT VENTURE
PPL had drilled first exploratory well Adam X-1 in Hala Block during 2007 which resulted in a gas / condensate discovery. Plant is operating at reduced rate due to change in reservoir behavior; water and sand production started from Upper Basal formation. For optimizing the production and to mitigate sand problem, a sand trap was installed in July 2011 and it has been recently de-commissioned in view of well behavior. Hala is basically LPG recovery field.

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PREPARATION OF PROCESS DESIGN DOCUMENTS

3.1. The Block Flow Diagrams (BFDs)

BFD shows overall processing picture of a chemical complex, flow of raw materials and products may be included on a BFD. BFD can either be Block Flow Process Diagram Block Flow Plant Diagram

BLOCK FLOW PROCESS DIAGRAM

Block Flow Process Diagram is similar to sketches in material and energy balances.

BLOCK FLOW PLANT DIAGRAM

Block Flow Plant Diagram gives a general view of a large complex plant.

3.2. The Process Flow Diagrams (PFDs)

PFD (or SFD- System Flow Diagram) shows relationship between major components in a system. A PFD also tabulates process design values for the components in different operating modes, typical minimum and maximum values. A PFD shouldnt show minor components, the piping systems, piping ratings and designations.

3.3. Heat and Material Balance (H&MB)

Heat and mass balance is a document produced by process design engineers while designing a process plant. A heat and mass balance sheet represents every process stream on the corresponding PFD in terms of the process conditions.

3.4. The Piping and Instrumentation Diagrams (P&IDs)

P&ID displays the interconnection of process equipment and the instrumentation used to control the process.
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3.5. The Plot Plans

Plan or map drawn looking down on plant (drawn to scale with all major equipment identified).

3.6. Process Simulation

Process simulation is a model-based representation of chemical, physical, biological, and other technical processes and unit operations in software. The software has to solve the mass and energy balance to find a stable operating point. The goal of a process simulation is to find optimal conditions for an examined process. This is essentially an optimization problem which has to be solved in an iterative process. .They include CAMCAD, HYSYS, Aspen Plus ,Ascend , Hysim ,distil simu, MASSBAL etc. I practiced HYSYS for the certain Oil and Gas processing unit and it helped me to get familiar with simulation environment and its working tools.

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PROCESS DESIGN CALCULATION OF PIPELINES SYSTEM & MAJOR PROCESS UNITS

4.1. Introduction with Transient Flow Regimes

Slug flow can pose serious problems to the designer and operator of two-phase flow systems. Prediction of slug characteristics is essential for the optimal, efficient and safe and economical feasible design and operation of two-phase gas-liquid slug flow systems. Some operations causing slugging include slugging caused by pigging, large pressure impacts, pigging problems, fatigue, high frictional pressure loss, end of production when low flow rates

SLUG PHENOMENA
When liquid and gas are flowing together in a pipeline, the liquid can form slugs that are divided by gas pockets. The formation of liquid slugs can be caused by a variety of mechanisms: 1. Hydrodynamic effects (surface waves) 2. Terrain effects (dip in pipe layout)

1. Hydrodynamic effects
Hydrodynamic or normal slug flow occurs at moderate gas and liquid flow rates, and hence is commonly encountered in multiphase pipelines. Hydrodynamics slug-flow is

characterized by a series of Taylor bubbles (gas pockets) separated by liquid slugs. In upward flow, the Taylor bubbles are symmetrical.

2.

Terrain effects

Terrain-induced slugging and riser-induced slugging are both classified as severe slugging, and characterized by liquid accumulation at low points. The gas upstream is compressed until it overcomes the gravitational head of the liquid; thereby creating a long liquid slug that is pushed in front of the expanding gas upstream.It is worth noticing that terrain slugging occurs for relatively low liquid and gas flow rates.
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4.2. Hydraulic Calculations of Process Piping

4.2.1.

HYDRAULIC DESIGN
1. Hydraulic balance 2. Pressure drop of piping 3. Pipe inside diameter 4. Pressure drop hand calculation by funning equation 5. Line sizing 6. Calculation of Le 7. Pressure drop of others 8. Pressure drop and flow control by control valve 9. Max suction pressure and max shut-off pressure 10. NPSH 11. HFD (hydraulic flow diagram) 12. Hydraulic hand calculation

4.3. Separators
Separators can be vertical, spherical, or horizontal, and typically employ a series of baffles to separate the gas from the liquid hydrocarbons. A horizontal separator is used when the gas-to-liquid hydrocarbons ratio is large; a vertical separator is used when the gas-to-liquid hydrocarbon ratio is small; and a spherical separator is used when the gas-to-liquid hydrocarbon ratio is in the intermediate range. When wellhead pressures are high, a series of separators may be operated at sequentially reduced pressures . Three principles used to achieve physical separation of gas and liquids or solids are momentum, gravity settling, and coalescing. The purpose of separators is to split the flow into desirable fractions.

Gravity Separation
The followings are formulas for Stokes Law, Intermediate and Newton's

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4.3.1.

SPECIFYING SEPARATORS

Separator designers need to know pressure, temperature, flow rates, and physical properties of the streams as well as the degree of separation required. It is also prudent to define if these conditions all occur at the same time or if there are only certain combinations that can exist at any time. If known, the type and amount of liquid should also be given, and whether it is mist, free liquid, or slugs.

4.3.2. DESIGN APPROACH

Calculate gas and liquid density. Calculate mass flow rate. Calculate particle diameter. Calculate drag coefficient (C) (appendix A) Calculate Reynolds no. On the basis of Reynolds use Stokes law, Intermediate law, Newtons law . Calculate terminal velocity and gas flow Assume diameter based, calculate length. Now based on L/D ratio check the feasibility of the separator. See Annexure G
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4.4. Heat exchangers

A heat exchanger is a specialized device that assists in the transfer of heat from one fluid to the other. In the most efficient heat exchangers, the surface area of the wall between the fluids is maximized while simultaneously minimizing the fluid flow resistance. There are two major different designs of heat exchangers: shell and tube, and plate heat exchanger. The most typical type of heat exchanger is the shell and tube design while plate heat exchanger is typically more efficient than the shell and tube design.

SHELL & TUBE EXCHANGER

A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. It consists of a tube bundle enclosed in a cylindrical casing called a shell. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. There are two basic types of shell-and-tube exchangers. The first is the fixed tube sheet unit, in which both tube sheets are fastened to the shell and the tube bundle is not removable. The second type of shell-and-tube unit has one restrained tube sheet, called the stationary tube sheet, located at the channel end. Differential expansion problems are avoided by use of a freely riding floating tube sheet at the other end or the use of U tubes. Shell-and-tube exchangers are designed and fabricated according to the standards of the Tubular Exchanger Manufacturers Association (TEMA).

4.4.2. DESIGN GUIDELINES

References: Hewitt et al Process Heat Transfer p267, Kern Process Heat Transfer Chapter 7, p127 and Perry Section 11 p11-0 to p11-19 Definitions Heat exchanger configurations are defined by the numbers and letters established by the Tubular Exchanger Manufacturers Association (TEMA). Refer to Appendix V for full details. For example: A heat exchanger with a single pass shell and multi-pass tube is defined as a
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1-2 unit. For a fixed tube-sheet exchanger with removable channel and cover, bonnet type rear head, one-pass shell 591mm (231/4in) inside diameter with 4.9m (16ft) tubes is defined SIZE 23-192 TYPE AEL. Tube Diameter The most common sizes used are 3/4"od and 1"od Use smallest diameter for greater heat transfer area with a normal minimum of 3/4"od tube due to cleaning considerations and vibration.1/2"od tubes can be used on shorter tube lengths say < 4ft. The wall thickness is defined by the Birmingham wire gage (BWG) details are given in Appendix XI (Kern Table 10) Tube Number and Length Select the number of tubes per tube side pass to give optimum velocity 3-5 ft/s (0.9-1.52 m/s) for liquids and reasonable gas velocities are 50-100 ft/s(15-30 m/s). If the velocity cannot be achieved in a single pass consider increasing the number of passes. Tube length is determined by heat transfer required subject to plant layout and pressure drop constraints. To meet the design pressure drop constraints may require an increase in the number of tubes and/or a reduction in tube length. Long tube lengths with few tubes may give rise to shell side distribution problems. Tube Layout, Pitch and Clearance Definitions and Nomenclature B PT C baffle spacing (pitch) tube pitch clearance

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do D

tube outside diameter shell inside diameter

Tube pitch is defined as P T = do + C Triangular pattern provides a more robust tube sheet construction. Square pattern simplifies cleaning and has a lower shell side pressure drop. Typical dimensional arrangements are shown below, all dimensions in inches. Tube od (in) 5/8 3/4 1 11/4 11/2 Square Pitch (in) 7/8 1 Note 1 Note 2 11/4 19/16 17/8 Triangular Pitch (in) 25/32 15/16 or 1 11/4 19/16 17/8 Note 1 Note 12

Note 1 for shell 12 pitch (square) 13/16 Note 2 for shell 12 pitch (square) 15/16 Table above uses minimum pitch 1.25 times tube diameter i.e. clearance of 0.25 times tube diameter. Smallest pitch in triangular 30 layout for turbulent / laminar flow in clean service. For 90 or 45 layout allow 6.4mm clearance for tubes for ease of cleaning. Shell Diameter The design process is to fit the number of tubes into a suitable shell to achieve the desired shell side velocity 4ft/s(1.219m/s) subject to pressure drop constraints. Most efficient conditions for heat transfer is to have the maximum number of tubes possible in the shell to maximize turbulence. Preferred tube length to shell diameter ratio is in the range 5 to 10.
28

Tube count data are given in Perry Table 11-3 where the following criteria have been used 1) Tubes have been eliminated to provide entrance area for a nozzle equal to 0.2 times shell diameter 2) Tube layouts are symmetrical about both the horizontal and vertical axes 3) Distance from tube od to centerline of pass partition 7.9mm (5/16) for shell id <559mm (22in) and 9.5mm (3/8) for larger shells. Heat Transfer Area Using the maximum number of tubes, subject to adequate provision for inlet nozzle, for a given shell size will ensure optimum shell side heat transfer in minimizing tube bundle bypassing. The heat transfer area required design margin is then achieved by adjusting the tube length subject to economic considerations. On low cost tube materials it may be more economical to use standard lengths and accept the increased design margin. It is a common practice to reduce the number of tubes to below the maximum allowed particularly with expensive tube material. In these situations the mechanical design must ensure suitable provision of rods, bar baffles, spacers, baffles to minimize bypassing and to ensure mechanical strength. Baffle Design Definitions Shellside cross flow area as is given by Where D B C PT shell i.d. baffle spacing clearance between tubes tube pitch

29

Minimum spacing (pitch) Segmental baffles normally should not be closerthan 1/5th of shell diameter(ID) or 50.8mm(2in) whichever is greater. Maximum spacing (pitch) Spacing does not normally exceed the shell diameter. Tube support plate spacing determined by mechanicalconsiderations e.g. strength and vibration. Maximum spacing is given by Most failures occur when unsupported tube length greater than 80% TEMA maximum due to designer trying to limit shell side pressure drop. Refer to attachments. Baffle cut Baffle cuts can vary between 15% and 45% and are expressed as ratio of segment opening height to shell inside diameter. The upper limit ensures every pair of baffles will support each tube. Kern shell side pressure drop correlations are based on 25% cut which is standard for liquid on shell side When steam or vapour is on the shell side 33% cut is used. Baffle pitch and not the baffle cut determines the effective velocity of the shell side fluid and hence has the greatest influence on shell side pressure drop. Horizontal shell side condensation require segmental baffles with cut to create side to side flow. To achieve good vapour distribution the vapour velocity should be as high as possible consistent with satisfying pressure drop constraints and to space the baffles accordingly.

30

Baffle clearances The edge distance between the outer tube limit (OTL) and the baffle diameter has to be sufficient to prevent tube breakthrough due to vibration. For example fixed tube-sheet clearances are shown below. Refer to Perry p11-11 for floating head clearances. Shell inside diameter mm (in) 254(10) to 610(24) 635(25) Clearance shell id and OTL mm (in) 11(17/16) 13(1/2)

Tube-sheet Layout (Tube Count)(Ref 4, page 577) Bundle diameterDb can be estimated using constants shown:

Where do Nt

tube o.d. number of tubes Triangular Pitch pt= 1.25 do

Number Passes K1 n

0.319 2.142

0.249 2.207

0.175 2.285

0.0743 2.499

0.0365 2.675

Square Pitch pt= 1.25 do Number Passes K1 n 0.215 2.207 0.156 2.291 0.158 2.263 0.0402 2.617 0.0331 2.643 1 2 4 6 8

Fouling Considerations

31

Typical fouling coefficients are shown inAppendix VII. It can be shown that the design margin achieved by applying the combined fouling film coefficient is given by:

Where AC is the clean HTA , Af is the dirty or design HTA and UC is the clean OHTC. Results for Typical Fouling Coefficients (British Units) Fouling Resistances Inside 0.002 0.002 0.002 0.001 Outside 0.001 0.001 0.002 0.001 Fouling Coefficients Inside 500 500 500 1000 Outside 1000 1000 500 1000 Combined 333 333 250 500 Clean OHTC 50 100 50 50 1.3 1.2 1.1 Design Margin 1.15

Corrosion Fouling Heavy corrosion can dramatically reduce the thermal performance of the heat exchanger. Corrosion fouling is dependent on the material of construction selection and it should be possible to eliminate altogether with the right choice. However if economics determine that some corrosion is acceptable and no data is available from past experience an allowance of 1/16in (1.59 mm) is commonly applied. Design Margin The design margin to be applied to the design is based onthe confidence level the designer has regarding the specific application and the future requirements for multipurpose applications. Design of condensers for multipurpose use, where a wide possible variation in flow conditions can exist, provides a particular problem in this regard. It is standard practice to apply a design margin of 15% to the design (dirty) heat transfer area with the result that this is applied to the design margin resulting fromthe application of the fouling film coefficients discussed previously giving an added safety factor.

32

Pressure Drop For process design using a simulation the following preliminary conservative estimates are given for pressure drops due to friction. Note an additional pressure change occurs if the exchanger is placed vertically. Initial Process Design Pressure Drop Estimates Process Description Liquid streams with Pressure Drop (psi) no 10 Pressure (kPa) 70

phase change Vapor streams with no 2 14

phase change Condensing streams Boiling streams 2 1 14 7

AIR COOLED HEAT EXCHANGER

The Air-cooled heat exchanger is a device for rejecting heat from a fluid or gas directly to ambient air. When cooling both fluids and gases, there are two sources readily available, with a relatively low cost, to transfer heat to air and water.

4.4.3. DESIGN GUIDELINES

The basic heat transfer relationships that exist for shell and tube exchangers also apply to the design of an air-cooled heat exchanger. However, there are more parameters to be considered in the design of an air-cooled exchanger. Since the air-cooled heat exchanger is exposed to changing climatic conditions, problems of control of the air cooler become relevant. A decision must be made as to what the actual ambient air temperature to be used for the design. Some of the governing factors in the design of the air cooler are: Tube diameter Tube length Fin height
33

Number of tube rows Number of passes Face area Horse power availability Plot area

Since there are many variables, normally there many solutions, however the designer attempts to find the optimum economic design given these factors.

4.5. Towers
Towers are used for fractionation. Fractionation is a unit operation utilized to separate mixtures into individual products. Fractionation involves separating components by relative volatility (). The difficulty of a separation is directly related to the relative volatility of the components and the required purity of the product streams.

DE-ETHANIZER
De-ethanizer is the distillation column in a gas processing plant where ethane is separated from a natural gas or natural gas liquids. It is separated from the natural gas liquids to stabilize the liquid petroleum gas. The ethane is returned to the gas stream.

DE-BUTANIZER
A debutanizer is a type of fractional distillation column used to separate butane from natural gas during the refining process. Fractional distillation, as occurs in a debutanizer, is the separation of a fraction a set of compounds that have a boiling point within a given range from the rest of the mixture.

STRIPPING TOWERS
VOCs, once in the ground, can be present for a very long time. Even when they reach an aquifer, the speed of flow is often measured in just a few minutes per year.
34

Contamination may be found by chance in springs and wells or when dewatering construction sites. Or it may be surveyed and quantified when pollution, recent or long past, is known to have occurred. The necessity for remediation is most immediate where a spring or well is needed for use, or where excavation water is too polluted to be disposed of without treatment. Stripping by packed tower aeration offers an effective and economical approach to many VOC contamination scenarios and Forbes has considerable experience in the design and fabrication of stripping installations.

4.5.1. DESIGN
In order to determine the design parameters for a fractionation problem, the following method is recommended: 1. Establish feed composition, flow rate, temperature, and pressure. 2. Make product splits for the column and establish condenser temperature and column pressure. From column pressure, calculate the reboiler temperature. 3. Calculate minimum number of theoretical stages from the Fenske equation from Eq 19-3 illustrated in the GPSA manual 4. Calculate minimum reflux rate from the Underwood equations from Eq 19-7 and 19-8 illustrated in the GPSA manual. 5. Obtain theoretical stages/operating reflux relation from Fig. 19-7 illustrated in the GPSA manual. 6. Adjust actual reflux for feed vaporization if necessary from Eq 19-9 and 19-10 illustrated in the GPSA manual.

4.6. Pumps
The most common types of pumps used in gas processing plants are centrifugal and positive displacement. Occasionally regenerative turbine pumps, axial-flow pumps, and ejectors are used. Modern practice is to use centrifugal rather than positive displacement pumps where possible because they are usually less costly, require less maintenance, and less space.

35

POSITIVE DISPLACEMENT PUMPS Positive displacement (PD) pumps work by allowing a fluid to flow into some enclosed cavity from a low-pressure source, trapping the fluid, and then forcing it out into a highpressure receiver by decreasing the volume of the cavity. Some examples of PD pumps are: fuel and oil pump in most automobiles, the pumps on most hydraulic systems, and the heart of most animals. Some general types of the positive displacement pump areas below:

a) Reciprocating Pump Reciprocating pumps create and displace a volume of liquid, their displacement volumes, by action of a reciprocating element. Liquid discharge pressure is limited only by strength of structural parts. A pressure relief valve and a discharge check valve are normally required for reciprocating pumps. Reciprocating pumps can be further classified into three types of pump as below, i) Piston Pumps ii) Packed Plunger Pumps iii) Diaphragm Pumps

b) Rotary Pump Rotary pumps function with close clearances such that a fixed volume of liquid is displaced with each revolution of the internal element. Rotary pumps include: i) Gear Pump ii) Lobe Pump iii) Vane Pump iv) Screw Pump CENTRIFUGAL PUMPS Centrifugal pumps are dynamic pumps. A centrifugal pump raises the pressure of the liquid by giving it a high kinetic energy and then converts it into pressure energy before the fluid exits the pump. It normally consists of an impeller (a wheel with blades), and some form of housing with a central inlet and a peripheral outlet. The impeller is mounted on a rotating shaft and enclosed in a stationary casing. Casings are generally of two types: volute and

36

circular. The impeller design and the shape of the casing determine how liquid is accelerated though the pump. Centrifugal pumps are used in more industrial applications than any other kind of pump. This is primarily because these pumps offer low initial and upkeep costs. Traditionally these pumps have been limited to low-pressure-head applications, but modern pump designs have overcome this problem unless very high pressures are required. The single-stage, horizontal, overhung, centrifugal pump is by far the most commonly type used in the chemical process industry. SELECTION OF PUMP Basically, pump selection is made on the flow rate and head requirement and with other process considerations, such as material of the construction pumps for the corrosive chemical service or for the fluid with presence solids in the stream. PERFORMANCE CURVE Operating characteristics of centrifugal pumps are expressed in a pump curve. Depending on impeller design, pump curves may be "drooping," "flat," or "steep." Pumps with drooping curves tend to have the highest efficiency but may be undesirable because it is possible for them to operate at either of two flow rates at the same head. The influence of impeller design on pump curves is discussed in detail in Hydraulic Institute Standards.

4.6.1. DESIGN
Process Requirements Parameters
In designing the pump, the knowledge of the effect of parameters; such as pump capacity, NPSH, pumping maximum temperature, specific gravity, fluid viscosity, fluid solid content, and the other process requirements are very important. All of these parameters will affect the selection and design of the pump which will affect the performance of the pump in the process. Flow Rate Pump capacity is a parameter plays an important role when selecting the pump. Capacity means the flow rate with which liquid is moved or pushed by the pump to the desired point in the process. It is commonly measured in either gallon per minute (gal/min)
37

or cubic meters per hour (m3/hr). The capacity usually changes with the changes in operation of the process. A minimum required flow rate need to be specified, this is important to determining if a minimum flow bypass is required for the selected pump to avoid pump overheating and mechanical damage. NPSH NPSH as a measure to prevent liquid vaporization or called cavitation of pump. Net Positive Suction Head (NPSH) is the total head at the suction flange of the pump less the vapor pressure converted to fluid column height of the liquid. The design engineer should always remember that pumps can pump only liquids, not vapors because when a liquid vaporizes its volume increases greatly. For example: 1ft 3 of water it will vaporize to produce 1700ft3 of steam. This will cause the rise in temperature and pressure drop in the fluid and pump will stop functioning because it has not sufficient suction pressure present. Design Temperature Pumping maximum temperatures is important in deciding pump construction style and pump cooling and mechanical seal requirements. The minimum operating temperature is to ensure that the material has adequate impact strength. Specific Gravity Specific gravity is parameter determines the pump head required to produce a desired pressure increase. For pumps with limited head capability such as centrifugal pumps, it affects pressure rise capability. Pump power requirements are also affected by specific gravity. Viscosity Viscosity is important in the selection of pump type and has a significant effect on centrifugal pump performance. Minimum values of viscosity are important in determining rotary pump (positive displacement pump) performance, while maximum viscosity is important in determining debits to centrifugal pump performance. Abrasives Fluid solid content will affect the pump design. It affected the aspects of the design for the flow characteristic, consideration design of erosion resistance, flow passage size, impeller

38

style, peripheral speed, design features to disintegrate large particles, and shaft sealing design. This parameter has to be added in the data sheet for design. Flexibility Other process requirement such as flexibility for expansion should be consider as well. This is important for future capacity expansion; it helps to minimize the cost of expansion because to replace the pump will be a large sum of money. Working capacity of pump should always be design for more than 20% extra design capacity.

4.7. Compressors
RECIPROCATING COMPRESSORS
Reciprocating compressor ratings vary from fractional to more than 40,000 hp per unit. Pressures range from low vacuum at suction to 30,000 psi and higher at discharge for special process compressors. Reciprocating compressors are furnished either single-stage or multi-stage. The number of stages is determined by the overall compression ratio. The compression ratio per stage (and valve life) is generally limited by the discharge temperature and usually does not exceed 4, although small-sized units (intermittent duty) are furnished with a compression ratio as high as 8.

CENTRIFUGAL COMPRESSORS
A multi-wheel (multi-stage) centrifugal compressor is normally considered for inlet volumes between 500 and 200,000 inlet acfm. A single-wheel (single stage) compressor would normally have application between 100 and 150,000 inlet acfm. A multiwheel compressor can be thought of as a series of single wheel compressors contained in a single casing. Most centrifugal compressors operate at speeds of 3,000 rpm or higher, a limiting factor being impeller stress considerations as well as velocity limitation of 0.8 to 0.85 Mach number at the impeller tip and eye. Recent advances in machine design have resulted in production of some units running at speeds in excess of 40,000 rpm. Centrifugal compressors are usually driven by electric motors, steam or gas turbines (with or without speed-increasing gears), or turbo expanders.
39

4.7.1. DESIGN
There is an overlap of centrifugal and reciprocating compressors on the low end of the flow range according to Fig-13-3 titled Compressor Coverage Chart, illustrated in the GPSA manual. The selection of an appropriate compressor is based upon it. This figure covers the normal range of operation for compressors of the commercially available types. Using this chart it is inferred that Compressor K-103, based on an inflow of 92.73 ACFM and discharge pressure of 1175 psig, can be designed either as a single-stage Centrifugal pump or a multi-stage Reciprocating pump. See Annexure H.

4.8. Storage
The selection section contains the explanation for the suitability of types of tank system used in processing industries, which are based on the environmental regulations, location, and process materials involved.

4.8.1. GENERAL DESIGN CONSIDERATIONS

Storage vessels containing organic and non organic liquids and vapors can be found in many industries, including;

(1) Petroleum producing and refining, (2) Petrochemical and chemical manufacturing, (3) Bulk storage and transfer operations, and (4) Other industries consuming or producing liquids and vapors.

Liquids and vapors in the bulk storage and transfer operations can be organic or hydrocarbon in nature. All those chemical should keep in the right storage tank. Design and safety concern has come to a great concern as reported case of fires and explosion for the storage tank has been increasing over the years and these accident cause injuries and fatalities.

40

LPG STORAGE TANK

The two main forms of LPG are commercial butane and commercial propane. LPG may be liquefied by moderately increasing the pressure or by reducing the temperature. Refrigerated storage is used by gas suppliers to store large volumes of LPG. The main form of LPG storage is in special tanks known as 'pressure tanks'. Commonly these pressure tanks are termed 'bulk tanks' or LPG Bullets. because LPG has a high coefficient of expansion in its liquid phase, the tanks are never completely filled with liquid (tanks are filled to approximately 85% of their water capacity), the remaining space being taken up with vapor (often referred to as the vapor space) to facilitate expansion without allowing the liquid to become 100% full (often known as hydraulically full). Most LPG storage tanks in standby-plant service are steel, non-refrigerated pressure vessels. Tanks are available in many sizes for both aboveground and underground service. New propane tanks are built to ASME standards and are designed for at least 250 psig working pressure. Common tank sizes and approximate dimensions are shown in the chart below. Larger industrial and commercial applications generally use 18,000 gallon and larger tanks.

Technical Specification
Standard Design As per ASME sec VIII Div 1 Pressure Vessel Code Pressure Design Design Temperature (atm) range Hydraulic Test Pressure Joints efficiency Radiographs Manhole Flanging Gates Thickness Diameter Length Weight 18.0 bar -20 / +50 C 25.0 bar 0.85 100 % 1 # ASA 300 8 6 mm to 50 mm 600 mm to 3000 mm Up to 18 Meters Long 3000 To 80000 Kg
41

Typical sizes available

2, 4 & 6 tons 8 & 10, Tons 12 & 15 Tons 18 & 20 Tons 26 & 30 Ton 36 & 40 Tons

NGL STORAGE TANKS

Natural gas processing plants remove NGLs in the natural gas stream due to liquid and Btu content. The very low temperatures or high pressures required to keep natural gas in its liquid state for storage.

DIESEL STORAGE TANKS

There are no specific legal requirements on how to store diesel or the quantity allowed either in workplaces or domestic premises. It is not, from a health and safety point of view, a particularly hazardous substance within the meaning of the Dangerous Substances and Explosive Atmospheres Regulations 2002 - its vapor flash point is too high. This means that its vapor will not ignite at normal room temperatures. Diesel does not require a Location Test Certificate or an approved handler. When stored in a bulk storage tank of more than 5,000 litres, a Stationary Container Test Certificate is required. This is also the case if the diesel is used in connection with an oil burning installation or an internal combustion engine, such as a generator. In this case, the threshold could be as low as 60 litres. There are exceptions where the diesel is used in a domestic oil burning installation. Diesel may be kept in a store room in a building, but the store room must have a fire resistance rating and the quantities allowed are limited, as is the package size.

42

CONCLUSION

Training at Pakistan Petroleum Ltd. is really a true learning experience. It has just not taught the utilization of bookish knowledge into practical field but also the ethics of professional life. This internship would remain the part of magnificence memories for the reason of PPLs hospitality & efforts of my seniors to teach their activities. It is expected that this technical guidance & professional knowledge would be helpful in my future studies.

43

REFERENCES

http://www.ehow.com/list_7472499_fundamentals-process-design.html http://www.msoe.edu/library/resources/standards/index.shtml http://www.ihs.com/products/industry-standards/organizations/api/index.aspx

http://www.techstreet.com/info/astm.tmpl
http://www.nfpa.org/categoryList.asp?categoryID=124&URL=Codes%20&%20Standards http://www.hse.gov.uk/electricity/standards.htm http://www.osha.net/federal-osha-standards-and-regulations.html http://oilgasprocessing.com/Gravityseparation.htm http://www.engineeringtoolbox.com/pfd-process-flow-diagram-d_865.html Gas Processing Suppliers Association (U.S.) Engineering data book : SI version / published as a service to the gas processing and related process industries by the Gas Processors Suppliers Association; compiled and edited in co-operation with the Gas Processors Association, 12th ed.Tulsa, Oklahoma : Gas Processors suppliers Association, 2004. Viska Mulyandasari, Heat Exchanger Selection and Sizing (Engineering Design Guideline), KLM Technology Group, Rev 03 November 2010. R. Mukherjee, Shell-and-tube heat exchangers, Chem. Eng. Progress, Feb 1998.

44

ANNEXURES

Annexure A
Electrical standards and approved codes of practice
ELECTRICAL AND POWER
Standard BS EN 61439 (many parts) BS 5266 Parts 1 to 10 also BS EN 50172 BS 5424 Parts 2 and 3, also IEC 60158 part 3 BS EN 60422 BS 5839 Parts 1 - 11, also PD6531:2010 BS EN 60079-30-2 BS 6423 BS 6626 BS EN 62305, 4 parts BS 7375 BS 7430 BS 7671 BS 7909 BS EN 50110 Parts 1 and 2 IEC 60479 Parts 1-4, also PD6519 BS EN 60529 BS EN 60947 Parts 1-8 1992 2001 - 2011 Specification for degrees of protection provided by enclosures (IP code) Specification for low voltage switch gear and control gear 2007 1983 2010 2006-2011 2010 1998 2008 - 2011 2008 - 2011 2004 - 2010 1994-2005 Electric surface heating Code of practice for maintenance of electrical switchgear and controlgear for voltages up to and including 1 kV Code of practice for maintenance of electrical switchgear and controlgear for voltages above l kV and up to and including 36 kV Code of practice for protection of structures against lightning Code of practice for distribution of electricity on construction and building sites Code of practice for earthing Requirements for electrical installations. IEE Wiring Regulations. Seventeenth edition Code of practice for temporary electrical systems for entertainment and related purposes. Operation of electrical installations Guide to effects of current on human beings and livestock. 2008 1988 - 2010 Monitoring and maintenance guide for mineral insulating oils in electrical equipment Fire detection & alarm systems for buildings 1985 - 1988 Specification for low voltage control gear Year 2009 - 2012 1999 - 2008 Description Low-voltage switchgear and controlgear assemblies Code of practice for emergency lighting

ELECTRICAL APPLIANCES
Standard Year Description

45

BS 1362 BS 1363 Parts 1 -5 BS EN (IEC) 60309, Parts 1,2, 4 BS EN 60320, Parts 1, 2 BS EN 60335, Many parts

1973 1995 - 2008 1999 - 2007 1999 - 2009

Specification for general purpose fuse links for domestic and similar purposes (primarily for use in plugs) 13 A plugs, socket-outlets and adaptors. Plugs, socket-outlets and couplers for industrial purposes. Appliance couplers for household and similar general purposes. Specification for safety of household and similar electrical appliances

ELECTROMAGNETIC COMPATIBILITY
Standard BS EN 61000-6-3,4 BS EN 61000-6-1,2 BS EN (IEC) 60801, Part 2 Year 2007 - 2011 2005 - 2007 1993 Description Electromagnetic compatibility. Generic emission standard. Electromagnetic compatibility. Generic immunity standard. Electromagnetic compatibility for industrial-process measurement and control equipment. Electrostatic discharge requirements

FLAMMABLE ATMOSPHERES
Standard EEMUA 181 EEMUA 186 BS EN 1127, Parts 1,2 Year 1995 1997 2007 -2008 Description Guide to risk based assessments of in-situ large Ex e & Ex n machines A Practitioners handbook electrical installation & maintenance in potentially explosive atmospheres Explosive atmospheres. Explosion prevention and protection. Basic concepts and methodology for mining PD CLC/TR 50404: BS EN 61241 PD CLC/TR 50427 BS EN ISO 10497 BS 7535 BS EN 60079, many parts BS EN 60079-6 BS EN 60079-2 BS EN 60079-5 BS EN 60079-1 BS EN 60079-7 BS EN 60079-11 2003 2004, 2005 2004 2004 1992 2004 2007 2007 2007 2007 2007 2007 Code of practice for avoidance of hazards due to static electricity. Electrical apparatus with protection by enclosure for use in the presence of combustible dusts. Assessment of inadvertent ignition of flammable atmospheres by radiofrequency radiation. Guide Testing of valves. Specification for fire type-testing requirements Guide to the use of electrical apparatus complying with BS 5501 or BS 6941 in the presence of combustible dusts Electrical apparatus for potentially explosive atmospheres. Replaced by BS EN 60079, but remains current. Explosive atmospheres. Equipment protected by oil immersion "o" Explosive atmospheres. Equipment protected by pressurized enclosures"p" Explosive atmospheres. Equipment protected by powder filling "q" Explosive atmospheres. Equipment protected by flameproof enclosures 'd' Explosive atmospheres. Equipment protected by increased safety 'e' Explosive atmospheres. Equipment protected by intrinsic safety 'i'

46

BS EN 60079-22-2 Energy Institute Model Code Of Safe Practice, Part 1 (IP1) Energy Institute Model Code Of Safe Practice, Part 15 (IP15) Energy Institute Model Code Of Safe Practice, Part 21 (IP21)

2007 2010 2005

Explosive atmospheres. Gas detection. Selection, installation, use and maintenance of detectors for flammable gases or oxygen Electrical Safety Code Area classification code for installations handling flammable fluids

2002

Guidelines for the control of hazards arising from static electricity

MACHINERY
Standard BS EN ISO 13850 BS EN 953 BS EN 13849 BS EN 982 BS EN 983 BS EN 1037 BS EN ISO 12100 BS EN 1088 PD 5304 BS EN 60204 many parts BS EN 61069, Parts 1-8 BS EN 61310, Parts 1,2,3 BS EN 61496, 3 parts PIAC 1991-1999 2008 2004 - 2008 1988 Year 2008 1997 - 2009 2008 1996 -2008 1996 -2008 1996 -2008 2010 2008 2005 Description Safety of machinery. Emergency stop. Principles for design. Safety of machinery. Guards. General requirements for the design and construction of fixed and movable guards Safety of machinery. Safety related parts of control systems. General principles for design Safety of machinery. Safety requirements for fluid power systems and their components. Hydraulics Safety of machinery. Safety requirements for fluid power systems and their components. Pneumatics Safety of machinery. Prevention of unexpected start-up Safety of machinery. General principles for design. Risk assessment and risk reduction. Safety of machinery. Interlocking devices associated with guards. Principles for design and selection. Safe use of machinery Safety of machinery. Electrical equipment of machines. Industrial-process measurement and control. Evaluation of system properties for the purpose of system assessment. Safety of machinery. Indication, marking and actuation. Safety of machinery. Electro-sensitive protective equipment. Printing industry advisory committee - safety at power operated paper cutting guillotines

47

Annexure B
Block Flow Process Diagram

48

Annexure C
Block Flow Plant Diagram

49

Annexure D
Process Flow Diagrams (PFDs)

50

Annexure E
Piping and Instrumentation Diagram (P&IDs)

51

Annexure F
Plot Plan

52

Annexure G
Separator Sizing

Separator Vessel Gas flow rate Gas Specific Gravity Gas MW Operating pressure Operating temperature Compressibility Viscosity Flowing gas density, dG Flowing oil density, dL Separator type Mass flow, M Particle diameter, Dp C(Re)2 From Fig. 7-4 GPSA Drag Coefficient, C Terminal Velocity, Vt Gas flow, Q Assume Dv Vessel length, L Diameter 3.5 4 4.5 5 60 0.75 21.72 500 100 0.9 .012 2.07 31.2 Horizontal, two-phase 39.8 4.92*10-4 4738 1.40 0.399 19.2 3.5 17.5 Length 17.5 15.315 13.615 12.25 ft/s ft3/s ft ft L/D 5 3.82 3.025 2.45 lb/sec ft MMSCFD

psig o F

cp lb/ft3

N.B. L/D ratio for horizontal separator is typically in the range of 2.5-5.

53

Annexure H
Compressor Design
Compressor K-103 Compressor Type Multi-stage Reciprocating with inter-cooling Number of stages Polytropic exponent Polytropic efficiency 2 1.284 78.23% Inlet stream Stream name Vapor fraction Temp. (oF) Pressure (psig) Molar flow (MMSCFd) Mass flow (lb/h) Molar enthalpy (Btu/lbmole) Overall compression ratio Compression ratio of 1 stage Compression ratio of 2nd stage Discharge temp. of 1st stage Discharge pressure of 1st stage Suction pressure of 2nd stage Intercooler inlet temp. Intercooler outlet temp. Intercooler duty Total calculated compressor duty Safety margin in compressor duty for mechanical losses Total HYSYS compressor duty 135 hp
54
st

Outlet stream 16 1.0000 236.25 1175 2.9197 7805.6 38.62

14 0.9994 28.7549 250 2.9197 7805.64 38.62 4.5 2.12 2.14 129.6 561.2 556.2 129.6 125 3.16 130.8

psi psi
o o

F F

hp hp

5%