T&E

Technology & Engineering Division

PETRONAS Sep-iSYS: Integrated Separation System for Slug, Sand, Inlet Heating and 3 Phase Separation
DD Technology 2 July 2012Council nd Date: 2 July 2012 Time: 9.00am 5.00pm Venue: Meeting Room, Level 23, PeTT 1

2012 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.

Objective
To seek DDTC endorsement to: 1) Adopt PETRONAS Sep-iSYS Integrated Separation System as a standard inlet separation system for PETRONAS Carigali Sdn. Bhd. 2) Implement Sep-iSYS at new and existing facilities

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Since its first installation in August 2011, Sep-iSYS has demonstrated the following benefits
CAPEX REDUCTION:

Up to 50%
REDUCTION IN FOOTPRINT AND WEIGHT

Compact system Fewer components compared to conventional separation system

Up to 50%
Online sand flushing and cleaning facilities

IMPROVED OPERABILITY, RELIABILITY, AND AVAILABILITY

No liquid carry over due to steady inlet flow Stable flow during slugging and minimum pressure drop Breaking down the emulsion before the liquid enters the separator

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Background
Sep-iSYS is a proprietary inlet separation technology developed by PETRONAS, with a patent filed on 31 January 2011. In July 2011, PETRONAS MC endorsed the commercial arrangement for SepiSYS and a Joint Commercialisation Agreement between PETRONAS Technology Ventures Sdn. Bhd. and NGLTech was executed. First unit installed in TGT FPSO for HLJOC, Vietnam and has been in continuous operation since August 2011.

Second unit being fabricated for D1 FPSO ONGC in India. First oil in December 2012.
Sep-iSYS technology was launched during WGC 2012, by PETRONAS COO, Datuk Wan Zulkifli as PETRONAS Technology Product

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Conventional Inlet Separation System

Conventional inlet separation systems are not suitable for systems prone to frequent and/or heavy slugging
Gas to compression

COMMON ISSUES:
Complex internals not suitable for waxy/fouling service Complex sand handling capability High pressure drop
Gas Outlet

Gas Cooler
Inlet Separator Inlet Heater

Water Outlet

2nd Heater

Oil Outlet

Compressor

High heating and cooling duty Very large vessel

Cooler Inlet

Scrubber
Slug Catcher
LC LC

Requires downstream system to be oversized

Low system reliability
Oil Outlet

Separator Heater
LC

Water Outlet

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Sep-iSYS Integrated Separator System

Unlike conventional inlet separation systems, Sep-iSYS is suitable for waxy and fouling services and for facilities that experience heavy slugging and motion condition TECHNICAL BENEFITS
Production Inlet
Gas Outlet

Integrated gas, liquid and sand separation with high efficiency Compact system thus reducing overall size, weight, equipment and controls

Scrubber

2
Separator Separator Separator

Sand Collector

Heater Water Outlet Oil Outlet

Increase availability due to online flushing system Protects downstream system from liquid carry over and oil/water slip through Energy efficient system Suitable for motion sensitive facilities and for handling waxy and fouling fluid
2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Sep-iSYS consists of three components:

1 2 3 Slug Catcher or Expended Pipe for slug handling Separator section for bulk gas/liquid separation Scrubber section to ensure high efficiency liquid droplet removal

HOW Sep-iSYS WORKS

Sep-iSYS Integrated Separator System

Production Inlet Gas Outlet

Scrubber

Separator Separator Separator Heater Sand Collector

Water Outlet

Oil Outlet

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Sep-iSYS Integrated Separator System

SC & Separator are pressure balanced P(SC) = P(S)

Production Inlet

Gas Outlet

Head during normal flow conditions

h1 Scrubber

RO

Separator Separator Separator

Sand Collector

Water Outlet

Oil Outlet
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2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

Sep-iSYS Integrated Separator System

Production Inlet Dh
Incremental head due to slugs SC & Separator are pressure balanced P(SC) = P(S)

Gas Outlet

Slug Hold-up Volume Head during normal flow conditions

h1 Scrubber

RO

Liquid Flow

Sand Droplets Settling Sand Collector

Separator Separator Separator

Water Outlet

Oil Outlet

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Key Advantages
OPERABILITY ADVANTAGES
Large Slug handling Capacity Suitable for waxy and fouling fluids Negligible pressure loss low compression power Stable liquid heating for emulsion breaking

DESIGN ADVANTAGES
Compact and light weight Minimal instrumentation Minimal separator internals in bulk liquid separator

Minimal heating duty

Minimal cooling duty High turndown ratio

Stable 3 phase separation even under slugging conditions

Allows easy and online sand removal High reliability

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

FIRST INSTALLATION: TGT FPSO (VIETNAM)

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The first unit of Sep-iSYS was installed on TGT FPSO for HLJOC in Vietnam and has been in continuous operation since August 2011.
Separator and Scrubber installation Slug Catcher/Expended Pipe installation

TGT FIELD INFORMATION

Field Name
Discovery Date Block Reserve Type Water Depth

TECHNICAL REQUIREMENT
Max Oil
Max Water Max Liquid Max Gas Slug Handling

PRODCUTION FACILITY INFO

Facility Name
Duty Operator Current Status

Te Giac Trang
Jan 2003 16-1 Oil/ Gas 45 m/ 149 ft

55,000 bopd
75,000 bwpd 130,000 blpd 120 mmscfd 70 m3

TGT FPSO
Oil Hoang Long Production since 2011

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TGT Vietnam Sep-iSys P&ID

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Realized weight savings of 53% and cost savings of 56% versus conventional separation system for TGT Vietnam
WEIGHT SAVINGS: COST SAVINGS:

53%
398 tons
Structural Piping & instrumentation Inlet Heater Scrubber

56%
4.55 mill
Structural Piping & Instrumentation Separator Internals Inlet Heater Scrubber Separator Slug Catcher

192 tons

Separator

Slug Catcher

1.98 mill
Savings :

USD 2.57 mill

Conventional

Sep-iSYS

Conventional

Sep-iSYS

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TGT Vietnam Sep-iSYS Process Performance

Separator level

Separator Monitoring NO flow instability Observed

Inlet Monitoring

Separator Pressure Slug Catcher DP/level

Slug Volume Measured: 30 m3

Click here -> 10 months Operating/ Process Data
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SECOND INSTALLATION: ONGC (INDIA)

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ONGC India Sep-iSYS P&ID (Second Unit)

The second unit of Sep-iSYS for D1 FPSO ONGC in India. Presently being fabricated and will be operational in December 2012.

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Realized weight savings of 47% and cost savings of 49% versus conventional separation system for ONGC
WEIGHT SAVINGS: COST SAVINGS :

47%
186 tons
Structural Piping & Instrumentation Inlet Heater Scrubber Separator Expended Pipe

49%
2.23 mill
Structural Piping & Instrumentation Inlet Heater

1.13 mill 98 tons

Scrubber Separator Internals Separator Expended Pipe

Savings :
Conventional Sep-iSYS Conventional

USD 1.1 mill

Sep-iSYS

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CASE STUDY: BOCPP

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Simulating Sep-iSYS based on BOCPP design parameters

Conventional System as currently specified for BOCPP CASE STUDY: Sep-iSYS Alternative for BOCPP

TECHNICAL REQUIREMENTS
Crude from wellhead gas from BEP-A
Total Liquid Oil Total Oil Associated Gas Slug Volume 130,000 blpd 30,000 bopd 130 mmscfd 15 m3

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CFD comparison of conventional separator system vs. Sep-iSYS for BOCPP

Conventional

Sep-iSYS

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Simulated weight savings of 52% and reduction in number of equipment of 55% versus conventional separation system for BOCPP
WEIGHT SAVINGS: COST SAVINGS:

52%
386 tons 147 tons
Level Transmitters/Gauges Associated Piping Crude Transfer Pump Sep-iSYS Separator B Separator A Slug Catcher

55%
6.4 mill
Structural Associated Piping Controls & Instrumentation Crude transfer Pump Scrubber Separator Internals Sep-iSYS Separator Slug Catcher

186tons tons 69

2.82 mill Savings :

3.58 mill
Conventional Conventional

Sep-iSYS

Sep-iSYS

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In summary, Sep-iSYS is able to deliver the expected benefits

CAPEX REDUCTION:

Up to 50%
REDUCTION IN FOOTPRINT AND WEIGHT

Compact system Fewer components compared to conventional separation system

Up to 50%
Online sand flushing and cleaning facilities

IMPROVED OPERABILITY, RELIABILITY, AND AVAILABILITY

No liquid carry over due to steady inlet flow Stable flow during slugging and minimum pressure drop Breaking down the emulsion before the liquid enters the separator

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

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Recommendation
To seek DDTC endorsement to: 1) Adopt PETRONAS Sep-iSYS Integrated Separation System as a standard inlet separation system for PETRONAS Carigali Sdn. Bhd. 2) Implement Sep-iSYS at new and existing facilities

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Next Steps
To consult with PCSB Project Managers to identify requirements for Sep-iSYS at existing and future facilities. To conduct feasibility study on requirements.

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THANK YOU

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BACKUP SLIDES

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Weight and Cost Estimation Basis

Weight Estimate Basis Associated Piping Instrumentation Structural 50% of equipment weight 20% of equipment weight 50% of total weight

Cost Estimate Basis (installed) Separator Scrubber Inlet Heater Associated Piping Instrumentation Structural Slug Catcher Vessel Expanded Pipe (Sep-iSYS)

USD/MT 15000 15000 20000 6000 20000 6000 15000 6000

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2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

TGT Vietnam Sep-iSYS unit Performance

SC differential pressure/level Separator Interface level

Differential pressure separator/scrubber

Separator liquid level

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Size Comparison
Slug Catcher Separator Scrubber Inlet Heater Conventional 4.0m x 16m 3.0m x 12.4m 2.2m x 4.5m 1.7 x 8m Conventional 2.7m x 10m 3.4m x 10.8m 2.0m x 4.0m 1.5 x 9m Conventional 2.7m x 6m 4.0m x 14m 4.0m x 14m Sep-iSYS 1.5m x 30m 2.2m x 9.0m 1.8m x 3.2m 1.5 x 6m Sep-iSYS 1.5m x 6.0m 2.6m x 9.0m 1.8m x 3.2m 1.5 x 6m Sep-iSYS 1.5m x 8.5m 3.7m x 14m 1.8m x 3.2m

TGT

ONGC

Slug Catcher Separator Scrubber Inlet Heater

BOCPP

Slug Catcher Separator A Separator B Scrubber

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Sep-iSYS Alternative for BOCPP (editable)

Gas from BEP-A

To Compression Trains

Slug Handling Device

Crude BODP-B FWS BODP-C FWS BODP-E FWS BOJT D-2 FWS BOJT D-1 FWS BODP-A & BODP-C

60 34
Polishing Scrubber
RO

2.0m(ID) x 2.2m(H) 10

3.7m(ID) x 14m(L)

20

Separator

10 14
PW System

Crude to BOP-A

To PW Degasser
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Conventional System at BOCPP (editable)

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Gas from BEP-A

14

Slug Catcher

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To Compression Trains

2.7m(ID) x 6m(L)

28 28

Crude BODP-B FWS BODP-C FWS BODP-E FWS BOJT D-2 FWS BOJT D-1 FWS BODP-A & BODP-C

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LP Separator A

24
LP Separator B

4m(ID) x 14m(L)

10

Crude to BOP-A

10
PW System
To PW Degasser

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OTHER SLIDES

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PCSB Operating Facilities experiencing liquid carry over issues

PCSB operation facilities with liquid carry-over experience based on GTS capacity check on separator performance:
PMO ABU PMO Resak PMO Duyong SKO West Lutong SKO Baram SKO Bokor SKO Baronia GTS is currently working on capacity check for PMO Dulang & Angsi, SBO-Sumandak

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New Separator Concept and Requirements

Large Slug handling Capacity Stable 3 phase separation even under slugging conditions Stable liquid heating for emulsion breaking Minimal heating duty Minimal cooling duty Negligible pressure loss low compression power Minimal separator internals in bulk liquid separator Minimal instrumentation High reliability High turndown ratio Allows easy and online sand removal Suitable for waxy and fouling fluids Compact and light weight

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Sep-iSYS Applications

All inlet separation systems, particularly those experiencing heavy slugging Deep-water developments

FPSOs
Systems handling waxy/fouling fluid

Retrofit & Debottlenecking existing facilities

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Issues With BOCPP Configuration

Complex internals Flow mal-distribution issues Large and unstable slug flow No sand handling capacity Unstable oil-water separation High liquid carry-over to downstream system Complex instrumentation, control & shutdowns

Low System Reliability/Availability High Maintenance Low Operability

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Track Record of Sep-iSYS

TGT FPSO for HLJOC, Vietnam. Started operations in September 2011, operating continuously to-date very satisfactorily. System designed for the following specifications:
Max Oil Max water Max liquid Max Gas Slug Handling Capacity = 55000 bopd = 75000 bwpd = 130000 blpd = 120 MMscfd = 70 m3

D1 FPSO for ONGC in India. Presently being fabricated and will be operational in December 2012. System designed for the following specifications:
Max Oil Max Water Max liquid Max Gas Handling Slug Handling Capacity = 50000 bopd = 50000 bwpd = 100000 blpd = 10.6 MMscfd = 10 m3
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