© Marc Roussel / Total

UTILITIES – PRODEM CHAPTER 30

Knowledge Sharing
Fransiska Citra Mariana
 GENERAL

● All facilities related to preparation and distribution of:

- Fuel gas, fuel oil
- Cooling water, refrigerant fluid
- Hot oil, steam
- Electric power
- Utility and instrument air
- Inert gas
- Chemicals
to fulfill the needs required by the process units

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 FUELS SYSTEMS
● Used in process applications for gas turbines, direct and indirect fire heaters,
reboilers, and in some few plants for generation of steam (e.g. in LNG plants)
● Include facilities for collection, preparation, and distribution of fuel to users

Fuel Oil
Used for
emergency
equipment

Fuel Gas
More
commonly
used

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 FUELS SYSTEM – DIESEL OIL

● Includes facilities of storage, pumping, and distribution of diesel oil at

a suitable pressure
- Users of diesel oil
• Gas turbines
- Gas turbines are fed diesel oil for limited period of time (start-up & shut down
of oil and gas units)

Average fuel consumption = 350

g/kW hr

Diesel oil tank capacity: about 1

hour to start on gas turbine with
diesel oil, and recover enough fuel
gas to feed the power station

Source: khi.co.jp

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 FUELS SYSTEM – DIESEL OIL (2)

• Fire water pumps

- Average fuel consumption of diesel engine = 200 – 250 g/kW/hr
- Diesel oil capacity : one day of diesel oil consumption
- Two-fire pump diesel engine must be considered (GS EP SAF 321 section
5.1)
• Emergency generators also use diesel oil

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 FUELS SYSTEM – DIESEL OIL (3)

● Equipment of a diesel oil system

- Atmospheric storage tank fed periodically by a truck or a supply boat. A
metallic filter is installed on this transfer line
- A filtering system composed of cartridge filters and coalescer to separate
solids and water contained in diesel oil
- Atmospheric intermediate tank to store the filtered diesel oil
- Particular surge atmospheric tanks to feed diesel oil users
• Typical surge time to size these surge tanks
- Turbogenerator = 1 hour
- Diesel generators for process = 2 hours
- Diesel generators for living quarters = 2 hours
- Fire water pumps = 24 hours
- Transfer diesel oil pumps
• Between tank and particular surge tanks
• To particular users

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 FUELS SYSTEM – FUEL GAS

● Purpose : provide a supply of fuel gas to turbines, gas engines, process

furnaces, blanketing, flares, purge at a controlled quality and a regulated
pressure
● Users
- High pressure fuel gas : gas turbines of the electrical power station,
gas turbines to drive main pumps or compressors
• Heavy-duty gas turbine = 15 to 25 barg
• Aircraft derivative gas turbine = 25 to 30 barg
- Low pressure fuel gas users (average pressure = 4 barg)
• Indirect fired heaters
• Direct fired heaters (fire tube, furnaces, hot oil or hot water)
• Stripping gas
• Flare or vent sweeping gas
• Purge gas (requirement can be consulted in GS EP ECP 103 section
12.8)

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 FUELS SYSTEM – FUEL GAS (2)

● Required fuel gas quality (Prodem chapter 23)

- Must be free of liquids and solids to prevent over temperature damage
to the gas turbines/burners/heater tubes of the furnaces
• Over temperature  due to hot points created by solid deposits and to
burning condensates with burners designed to burn gases
- Temperature must be maintained in a range of 10 – 20oC above the
higher value of the water dew temperature and the hydrocarbon dew
temperature at user inlet flange pressure
- Fuel gas must be flared during start-up period until fuel gas system
equipment has reached normal temperature
- Fuel gas as stripping gas in glycol regeneration unit must be dry and
free of hydrocarbon liquids at user flange inlet

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 FUELS SYSTEM – FUEL GAS (3)

● Required fuel gas quality (continued)

- Fuel gas pressure must be maintained at required constant value defined by
the user
- Corrosive agents
Presence of corrosive agents cause elevated temperature corrosion of
turbine nozzle and blading materials and ambient temperature corrosion
of control valves and systems
- When sulphur is present, the amount of H2S after treatment shall not exceed
10 ppmv (GS EP MEC 214)
- The range of the lower heating values shall not vary more than 10%
● Required fuel gas quantity
- Fuel shall be sufficient for 120% of maximum fuel requirement
- The efficiencies values of apparatus as follows can be adopted
• Indirect fired heaters 60%
• Direct heaters 70 – 80%
• Gas turbines 20 – 30% (according to gas turbine type)
• Gas engines 50%

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 FUELS SYSTEM – FUEL GAS (4)

● Considerations for fuel gas equipment

- Supply of fuel gas at required constant pressure
• Fuel gas must be produced at higher pressure to take account of pressure
losses in the fuel gas treatment system and in the pressure control
• Compression must be carried out if the pressure value is not sufficient
• If the pressure value is too high, reduction of gas pressure is obtained with a JT
valve
- Supply of fuel gas free of liquids
• Gas-liquid separator drum and/or scrubbers are used to remove liquid from gas
• To obtain a fuel gas temperature above 15 -20oC the higher value of the water
dew temperature, an electrical heater is commonly used
- Remark – To prevent liquid carry over through the user inlet flange, it is
recommended
• To design the piping to eliminate pockets
• To flare fuel gas during start-up period until fuel gas system equipment has
reached normal temperature

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 FUELS SYSTEM – FUEL GAS (4)

● Considerations for fuel gas equipment (continued)

- To ensure supply of fuel gas to be free of solids
• Just upstream the user inlet flange, a filter for solids must be installed
• Diameter higher than 5 – 10 micrometer usually installed as a part of fired heater
or turbine package
● Fuel gas surge capacity
- May be provided by the inlet KO drum or the gas-liquid separator

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 EXAMPLE OF UTILITY FLOW DIAGRAM FOR A FUEL
SYSTEM

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 EXAMPLE OF FUEL GAS BALANCE

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 COOLING WATER SYSTEMS
● Provided to remove heat as necessary in process sequences and
before storage of final products
● In oil & gas processing and conditioning plants it is necessary to cool
- Process stream
- Equipment auxiliaries
- Utilities
● Water is the traditional fluid for cooling
- Inlet temperature of water in HE > 30oC
- DeltaT < 10oC , for sea water this value must take account of local sea
water characteristics
- Minimum final temperature of fluid that can be cooled is approximately 8 –
12oC above water inlet temperature in the heat exchanger. 3-5oC when
plate exchangers are used

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 COOLING WATER SYSTEMS (2)

● Two types of cooling water system

- Once through
- Recirculated system
● The choice must be based on these factors
- Availability of water of satisfactory quality
- On process temperature requirements
- On equipment maintenance and operating costs

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 COOLING WATER SYSTEMS (3)

● Offshore cooling-water system of recirculated type

- Water quality
• Fresh water with anticorrosives and antiscaling additives
• In cold areas, the fluid circulated is glycolated (usually monoethylene glycol)
fresh water. Glycol concentration in Alwyn plant = 20% weight
• In offshore, the first load of fresh water can be brought from a supply boat, the
make-up can be taken from the desalted water network
- Equipment consideration
• Main pumps circulating cooling water would be provided with a 100% spare
• No spare for make-up pump, since it is used intermittently
• One heat exchanger in stand-by is always required

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 SIMPLIFIED UTILITY FLOW DIAGRAM FOR SEA WATER SYSTEM

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 EXAMPLE OF UTILITY FLOW DIAGRAM FOR A COOLING
WATER SYSTEM IN CLOSED LOOP

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 REFRIGERANT
● Selection of a refrigerant is generally based upon temperature
requirements, availability, economics, and previous experience
● In natural gas processing plant, ethane and propane may be at hand,
in olefins plant, ehtylene and propylene are readily available
● Example application : refrigerant used in LNG Plant PT Badak
● LNG Plant in PT Badak uses two types of refrigerant
- Propane refrigerant
- MR refrigerant
• N2 = 2.2%
• C1 = 41.2%
• C2 = 51.3%
• C3 = 5.3%

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 MR CYCLE LOOP IN PLANT 5 LIQUEFACTION – PT BADAK

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 HOT FLUID SYSTEMS

● Provided to supply heat as necessary in process sequences

● Necessity :
- To heat heavy crude oils to favor its stabilisation, dehydration, and desalting
- Bottom stream in reboilers of depropanisers, debutanisers, and condensate
stabiliser column
- Gas used to regenerate molecular sieves in gas or condensate drying units
● Pressurized heat water can be used in a recirculated system to process heavy
crude oil, where hot water is heated until a temperature of around 180oC
● Pressurized hot oil system is used where elevated temperatures are
required
- 230oto 300oC for gas used to regenerate molecular sieves
- 100 to 200oC for bottom stream in reboilers of depropanizers, in reboilers
of debutanizers, in reboilers of condensate stabiliser
● Steam is not used in oil field or gas field plants, only used in some LNG
plants

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 HOT FLUID SYSTEMS – HOT OIL

● Used in both liquid and vapor phases

● The types of oils used most commonly in the oilfield
• Alkylated derivatives of benzene and polyphenyls, used in majority of
applications up to 340oC
• Aryl ethers, stable up to 400oC
• Paraffin, non-toxic and environmentally friendly. The maximum operating
temperature is 300oC
● The advantage of hot oil include
• Low vapor pressure at ambient temperature
• Easy to handle
• Formulated for specific temperature range
• Better heat transfer properties than those or normally occuring hydrocarbons
● The drawbacks
• Escaping vapors are often environmentally undesirable
• Low heat-transfer properties

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 EXAMPLE OF UTILITY FLOW DIAGRAM FOR A HOT OIL
SYSTEM

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 HOT FLUID SYSTEM – HOT OIL

Total Seriola
mineral based heat transfer oil
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 ELECTRIC POWER SYSTEM
● The source of electrical energy for oil and gas processing plant must be
determined
● If purchased power is to be utilized, the voltage level and quality of power
available must be known
● Decisions are needed for e.g.
- Voltage levels of various users
- Motor characteristics
- Distribution voltage in the plant
- Shelters and enclosures for electrical gear
● Example of users in oil treatment unit
- Booster pumps (for oil expedition)
- Main oil pumps
- Condensate pumps
- Associated gas compressors
● Example of users in gas treatment unit e.g.
- Glycol pumps
- Refrigeration loop compressor

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 ELECTRIC POWER SYSTEM (2)
● Electric supply source for example
- CCVT (Closed Cycle Vapor
Turbogenerator)
- THEG (Thermal Electric Generator)
● CCVT is a turbine that uses vapor
for the working fluid as part of a
Source: web.mit.edu
closed thermodynamic system
- Such recirculating turbines follow the
Brayton cycle.

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 ELECTRIC POWER SYSTEMS (3)

● THEG
- THEGs depend upon a temperature
difference to “drive” the device – one
side needs to be hot and the other
side cold
- The temperature difference makes
the electrons on the hot side vibrate
more vigorously so they tend to
move towards the colder side
- This movement gives rise to current
that can be tapped off as electricity

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 AIR SYSTEMS

● Compressed air is used for

- Instrumentation purpose
- Air service purpose
● Specification for instrumentation purpose (as per GS EP INS 104 and
Prodem Chapter 30)
- The dew point temperature shall be 20oC below the minimum ambient
temperature
- Air receiver vessels shall be installed to maintain instrument air supply for
a minimum of 20 minutes at a full consumption rate
- Compressors, vessels and instrument air header shall be designed such
that the normal pressure shall be 7 barg at instruments supply point
- Instrument gas storage system shall be designed to provide instrument gas
supply for the same duration as UPS autonomy in the event of shutdown,
with a minimum of 20 minutes at full consumption rate
- Pressure drop shall not be more than 0.5 bar at max flow
- Low points and end points of all distribution manifolds shall be fitted with
drain valves

Knowledge Sharing 28
 EXAMPLE OF UTILITY FLOW DIAGRAM FOR INSTRUMENT AND SERVICE AIR
SYSTEM

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 AIR SYSTEMS (2)

● Equipment used in plant air systems include

• Air compressors
• Dry air systems
• Air receivers
- Two 100% compressor packages (both generally driven by electrical
motors) are used to compress air from atmospheric conditions to around 8
barg
- Service air is not always dried
- Two air dryer packages are used, each having a capacity equal to the total
amount of compressed dry air produced (one in service, one in stand-by)
- Drier air, after filtering, is stored in an air receiver provided for instrument
air retention
● Retention volume is determined to allow the delivery of a normal
instrument flowrate during 10 minutes

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 AIR SYSTEMS (3)

● In air compressor package, oil free centrifugal, rotary, screw or

reciprocating compressors may be used in air service
● Typical air pressure at discharge compressor package: 8 to 9 bar(g),
typical air temperature at discharge compressor package: 30-35oC

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 AIR SYSTEMS (4)

● Air dryers are provided for removal of moisture in dry-air systems.

● Wet, cooled, compressed air is passed through a desiccant filled
drying tower and emerges as a dry gas
● Usually are purchased as complete packages which include two
prefilters and afterfilters, drying agent, and regeneration system
- A prefilter must be furnished upstream of the air dryer to protect desicant
bed from contamination
- An after-filter of a similar type must be located downstream of the dryer to
tap out any desiccant that may be carried over with the dried gas
● Two drying towers are provided, one is regenerated while the other is
in use

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 AIR SYSTEMS (4)

● Basic air consumption data for instrument air

- Transmitter = 0.4 Sm3/hr intermittent consumption,
- Controller = 1 Sm3/hr permanent consumption
- Actuator = 1 Sm3/hr intermittent consumption

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 INCIDENTS RELATED TO UTILITIES

Knowledge sharing 34
Preliminary Incident Info
Incident Title: Fire inside CCVT A enclosure– GTS Y
Location: NPU-GTS Y Synergi :
Classification: INCIDENT Real Severity: 1 Date: 17/1/2015, at 09h40
Incident Description:
During site visit for navigation aid verification, a technician found CCVT
B shutdown. He intended to check the condition of CCVT A parameter
(whether it was capable to handle all GTS Y load).

When opening the enclosure of CCVT A, he found fire. He initiated

ESD-1 push button and close CCVT A fuel valve. He attempted to take
fire extinguisher inside RTU but he couldn’t open RTU door and he
took fire extinguisher from sea truck and extinguish the fire.
Incident Consequences:
No personal injured
GTS Y shutdown
Damage on CCVT A (to be verified further)
Immediate Actions:
Initiated ESD-1, closed fuel valve supply & extinguished fire
Incident Causes:
Liquid carry over to CCVT burner
Recommendations:
Recommendation will be given afterward after further investigation.
 REFERENCE

Main reference:
1. Prodem Chapter 30

Other reference
1. Prodem Chapter 10
2. Prodem Chapter 23
3. GPSA Data Book
4. GS EP INS 104

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and the entity making the presentation.

Disclaimer
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TOTAL GROUP does not assume any obligation to update publicly any forward-looking
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Accordingly, no reliance may be placed on the accuracy or correctness of any such
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Copyright
All rights are reserved and all material in this presentation may not be reproduced without
the express written permission of the TOTAL GROUP.
 BACKUP

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Knowledge Sharing 40
 BRAYTON CYCLE

• a-b Adiabatic compression in the inlet and

compressor
• b-c Constant pressure fuel combustion
• c-d Adiabatic, reversible expansion in the
turbine and exhaust nozzle
• d-a Cool the air at constant pressure back
to its initial condition

Source: web.mit.edu

Knowledge Sharing 41