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Gas Compression System HP/LP separator and Surge Vessel Operating

Envelope Study

Technical Report · August 2016

DOI: 10.13140/RG.2.2.32310.09288

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Prakash Bahadur Thapa

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Prakash Bahadur Thapa
Memorial University,
St. John’s, NL, Canada, A1B 3X5
Corresponding author: Email: pbt750@mun.ca; Tel: +1(709) 330-8666

Abstract

The facility study is double-bank two-stage (HP and LP), two-phase liquid/gas
separation at Crude flows through the inlet manifold. At the inlet manifold, it is
directed to one of the headers or the test header for well testing.

The HP header feeds the HP separator operating at a pressure of 10 – 12 barg,

while the LP separator (operating at a pressure of 2.5 -3.5 barg) is fed from low
pressure wells together with liquid from the HP separator. The LP separator
liquid output goes to the Surge vessel (operating at about 0.3 barg).

Gas from the Surge vessel (0.3 barg) is collected by use of gas ejector, boosted
to 2.5 barg, commingled with the gas from LP separator and fed into the 1st stage
of the AG Compressor.

Gas from the HP separator (10 – 12 barg) is let down to LP pressure (2.5 - 3.5
barg), commingled with LP gas and fed into 1 st stage of the AG Compressor. The
associated gas streams are compressed to a final discharge pressure of 120
barg as follows:

 1st stage compression (7.1barg)

1.0 OBJECTIVE

The objective of this study is to establish the production capacity limit of the gas plant
and hence ensure its technical and operational safety integrity. The study will be:

 Establish design, operating capacities for all process, utility and ancilliary
equipment specified in the Gas facility.

 Generate operating and system curves to determine safe and acceptable

limits for all units in this facility.

 Confirm technical integrity and HSE fit for all process/utility units in this
facility.

 Identify optimization opportunities and how they can be implemented

under prevailing operating conditions and envelope.

2.0 PROCESS DESCRIPTION

The facility study is double-bank two-stage (HP and LP), two-phase liquid/gas
separation at Crude flows to the station through the inlet manifold. At the inlet
manifold, it is directed to one of the headers or the test header for well testing.

The HP header feeds the HP separator operating at a pressure of 10 – 12 barg,

while the LP separator (operating at a pressure of 2.5 -3.5 barg) is fed from low
pressure wells together with liquid from the HP separator. The LP separator
liquid output goes to the Surge vessel (operating at about 0.3 barg).

Gas from the Surge vessel (0.3 barg) is collected by use of gas ejector, boosted
to 2.5 barg, commingled with the gas from LP separator and fed into the 1st stage
of the AG Compressor.

Gas from the HP separator (10 – 12 barg) is let down to LP pressure (2.5 - 3.5
barg), commingled with LP gas and fed into 1 st stage of the AG Compressor. The
associated gas streams are compressed to a final discharge pressure of 120
barg as follows:

 1st stage compression (7.1barg)

 2nd stage compression (18.0 barg)

 3rd stage compression (48.6 barg)

 4th stage compression (120 barg)

The discharge from the compressor will be tied into the Manifold.
3.0 METHODOLOGY

Equipment design specifications were sourced from manufacture data while

process and operating conditions were based on process simulation. HYSYS
process simulation and Excel spreadsheets were used to perform engineering
calculations and analyses of data.

4.0 COMPRESSOR INLET MANIFOLD

The inlet to the Gas Compressor skid consists of a manifold of the HP gas
header, LP gas header and the Surge Vessel gas outlet line (via the Ejector),
leading to a common compressor inlet header.

The compressor inlet piping is rated ANSI 150 (230psig maximum allowable
working pressure at 200 ). Details of the various headers are listed in the table
below:

Table 4.1.1 Details of the Gas Inlet manifold/headers

Header Size (Inch) Rating

LP Gas Header 8 150#

HP Gas Header 6 150#

Ejector Outlet Line 2 600#

Compressor Inlet Header 8 150#

4.1 EROSIONAL VELOCITIES

The erosional velocity criteria given in API PR 14E was used as the basis of
assessment for limits of safe flow velocities in the header to the 1st stage
compressor inlet scrubber. Liquid carry-over of 300 bbls/d (4% of Flow station
gross liquid production) is assumed.

According to API 14E,

Ve = C/(ρm )^0.5

Ve = erosional velocity (m/s)

C = empirical constant = 100 for solids-free continuous service.

ρm= Gas/liquid mixture density at flowing pressure and temperature.

Applying the above criteria, the threshold erosional velocity for the compressor
inlet piping was found to be 63.63 m/s. Operating flow velocity in header was
calculated to be 13.43 m/s Therefore the specified operating velocity is within
limits of erosional velocity and the header is not under erosion risk.

The operating envelope for the header in terms of flow throughput based on
erosional velocity limit is presented in Appendix 1. It shows that flow through the
header at the specified operating conditions does not result in a throughput
constraint and that the two-phase flow in the header (at the operating point) is
within the envelope.

5.0 Compressor

Specific Compressor Performance curves” was used as a guide to check the

operating envelope of the Compressor. The compressor runs at a constant
speed of 1400 RPM and the discharge is set at 121.3 barg at varying suction
pressure. From Appendix 2, the Gas Compressor system curves cover a flow
between 3.5 - 5.59 MMscfd of gas. A combination of the system and operating
lines generates the “operating envelope” (Appendix 2).

5.1 COMPRESSOR DRIVER

The AG Compressor system driver rating is between 630 – 960 KW over a

suction pressure range of 2.0 - 3.35 barg at varying capacity control and the
required power rating for the Compressor package is between 185 - 234 KW.
Appendix 3 shows that the compressor duty rating is within the design envelope.

6.0 SEPARATORS

The basic information of the separators in the Gas Compression train is given in
table 7.1.1 below. Integrated system operating envelope for the separators with
the associated ancillary units - nozzles, relief and control valves – are presented
in appendix XX.
Table 6.1.1 Separators Summary Data
ST nd rd
Vessel Data 1 Stage Suction 2 Stage Suction 3 Stage Suction 4th Stage Suction Discharge Fuel Gas KO
Scrubber Scrubber Scrubber Scrubber Scrubber Vessel

Size 914mm ID and 660mm ID and 559mm ID and 1575mm 457mm ID and 406mm ID and 324mm ID and
3294mm T/T 1676mm T/T T/T 1473mm T/T 1346mm T/T 2150mm T/T

Internals Wire mesh, Vortex Wire mesh, Vortex Wire mesh, Vortex Wire mesh, Vortex Wire mesh, Vortex Wire mesh, Vortex
Breaker Breaker Breaker Breaker Breaker Breaker

Inlet Device Schoepentoeter Half open pipe Half open pipe Half open pipe Half open pipe Half open pipe

Nozzles 8” Inlet, 8” gas outlet, 6” Inlet, 6” gas outlet, 2” 4” Inlet, 4” gas outlet, 2” 4” Inlet, 4” gas outlet, 3” Inlet, 3” gas 3” Inlet, 2” gas
2” liquid outlet liquid outlet liquid outlet 2” liquid outlet outlet, 2” liquid outlet outlet, 2” liquid outlet

Operating Pressure 2.5 barg 6.9 barg 17.6 barg 47.5 barg 120 barg 4.5 barg

Operating 37 49 49 49 49 25
Temperature

Maximum Operating 15.8barg 15.8barg 45.16barg 90.32barg 135.5barg 15.8barg

Pressure

Orientation Vertical Vertical Vertical Vertical Vertical Vertical

Separation Efficiency 98% 98% 98% 98% 98% 98%

6.1 SEPARATOR GAS HANDLING CAPACITY

The gas handling capacity of the separator is based on the minimum vessel
cross sectional area required for gas flow.

λmax=Q*max/ AG,min (m/s)

λmax=Q*max/( D2min/4)=fᵑfᶲ (m/s)

D=3.48(Q*max/ fᵑfᶲ)^0.5 (m)

AG,min is the cross-sectional area above the highest liquid level. (m2)

λmax is the maximum allowable gas load factor.

Q*max is the highest density corrected volumetric gas flowrate and is

defined as follows:

Q*max= QGmax (ρg/(ρl-ρg)

QGmax is the highest envisaged gas flowrate in m3/s.

Based on the above relation, the maximum allowable gas flowrate was calculated
for each of the gas scrubbers in the Gas Compressor train as well as the fuel gas
knock out vessel. The maximum allowable gas handling capacities for the
vessels are presented in Table 7.1.2 below.

Table 6.1.2: AG Scrubbers Capacities.

Scrubber Stage Max Allowable Gas Flow Rate Max Liquid Rate

1ST Stage Suction 9.16MMscfd 14217bpd

2ND Stage Suction 7.05MMscfd 7382bpd

3RD Stage Suction 7.82MMscfd 5237bpd

4TH Stage Suction 8.59MMscfd 3406bpd

Discharge Scrubber 10.87MMscfd 2505bpd

Fuel Gas KO Vessel 2.05MMscfd 1183bpd

6.2 SEPARATOR LIQUID HANDLING CAPACITY

This criterion was evaluated based on the liquid degassing criterion:

D 7608 QL, max L/( L- G) ) (m)

 QL,max is the maximum liquid flowrate (m3/s)

L is the length of vessel (m)

L is liquid dynamic viscosity

The equation above is based on Stokes law and in practice, bubbles larger than
200μm are assumed to be able to escape. Based on the above equations, the
liquid handling capacities of the scrubbers was found to be in the range 1183 -
14217 bbls/d.

6.3 SEPARATOR FEED INLET NOZZLE CAPACITY

This is based on the momentum criteria of the nozzle inlet devices which is
dependent on maximum flowrates. The criterion shall satisfy:

For no inlet device:

m V2m,in 1400 (Pa)

For half open pipe:

m V2m,in 2100 (Pa)

For schoepentoeter:

m V2m,in 8000 (Pa)

Where:

m is the mean density of the mixture in the feed pipe

m= (MG+ML) / (QG+QL) (kg/m3)

and Vm,in is the velocity of the mixture in the inlet nozzle

Vm,in = (QG+QL)/( d12/4) (m/s)

These criteria were used to test the suitability or otherwise of the inlet nozzle to
the scrubbers. Results of capacity checks for the vessels inlet nozzles are
summarises in Table 7.2.3 below. It shows that the nozzles capacities meet the
criteria.

Table 6.2.3 Nozzle Size Checks

Check for Check for Check for Liq

V2m,inρm V2g,outρg Vl,out Gas Inlet Gas Outlet Outlet
(m/s) Nozzle Nozzle Nozzle
Capacity Capacity Capacity
1st Stage Scrubber 440.89 440.89 0 SATISFIED SATISFIED SATISFIED
2nd Stage Scrubber 637.9 637.9 0 SATISFIED SATISFIED SATISFIED
3rd Stage Scrubber 1335.4 1335.4 0.001315 SATISFIED SATISFIED SATISFIED
4th Stage Scrubber 447.4 447.4 0.001994 SATISFIED SATISFIED SATISFIED
Discharge Scrubber 514.2 514.2 0.00199 SATISFIED SATISFIED SATISFIED
Fuel Gas KO Vessel Fill Fill Fill Fill Fill Fill

6.4 SEPARATOR GAS OUTLET NOZZLE CAPACITY

This also is derived from the momentum criteria and given as follows:

G V2g, out 4500

Where:

G is the gas density (kg/m3)

V2g,out is the gas outlet velocity (m/s).

The vessels gas outlet nozzles also satisfy the criteria as adequately sized and
therefore can handle the expected flows (Table 7.2.3).

6.5 SEPARATOR LIQUID OUTLET NOZZLE CAPACITY

The liquid outlet nozzle capacity calculation was based on the criterion that the
liquid velocity should not exceed 1m/s. This criterion together with the liquid
outlet nozzle diameter was used to check the adequacy of the liquid outlet
nozzle.

As shown in the Table 7.2.3 above, the liquid outlet velocities in the nozzles are
in the range 0 - 0.002m/s and the liquid capacity (QL, max) is 1,102 bpd which
satisfies the criterion.

7.0 RELIEF VALVE CAPACITY

The AG Compression Relief valves are of Anderson Greenwood Crosby API RP

520 and API Std. 526 were also utilized in the sizing of the 100% blocked flow of
the relief valves.

Details of specifications of the relief valves for the gas Solution facility are shown
in Table 7.1.1 below. Table of capacity checks on the Gas facility relief valves are
presented in Appendix XX. Generally, the relief valves are adequately sized for
the specified operating conditions.

Table 7.1.1 Relief Valve Properties

Description Manufacturer Size Set Pressure

1st Stage Discharge Anderson Greenwood 2J3 13.8 barg

Crosby

2nd Stage Anderson Greenwood 1-1/2G3 43.8 barg

Discharge Crosby

3rd Stage Discharge Anderson Greenwood 1E2 90.32 barg

Crosby

4th Stage Discharge Anderson Greenwood 1-1/2D2 135.5 barg

Crosby

Summary of the relief valves capacities rating result is shown in appendix 10 and table
below.

Table 7.1.2 Relief Valve Capacities: 100% Blocked Flow Capacities:

Description Required Rated Gas Required Installed Valve

Gas Capacity Valve Orifice Orifice Area
Capacity (MMscfd) Area (cm2) (cm2)
(MMscfd)

1st Stage 4.313 10.1 0.548 1.287

Discharge

2nd Stage 4.313 12.06 0.18 0.503

Discharge

3rd Stage 4.303 9.69 0.087 0.196

Discharge

4th Stage 4.14 8.5 .053 0.11

Discharge

The table above shows that the relief valves are adequately sized for the
operating conditions. 7.1 FLARE CAPACITY

The flare system was rated based on API 521. The flare stack diameter is 16”
and the flare height is 20m. Using the above mentioned API standard, the
capacity at 0.5 Mach was found to be 55.9MMscfd. This is higher than the
operating point of 4.3Mmscfd.
8.0 CONCLUSION

Facility Operating envelop has been developed for the AG compression system
and associated process utility units. Calculations and analysis of the systems
operating envelop show that the design capacities of gathering, compression and
export equipment are adequate for the envisaged maximum operating capacities
based on the expected throughput gas supply.

The range, margin and limits of safe operating conditions for the main equipment
and integrated units are shown in the operating envelop. It can be shown that the
operating conditions as specified in the design documents are within the systems
envelope.

9.0 REFERENCES

1. API RP 520 (sizing, selection and installation of pressure- Relieving

devices in refineries; Part 1-sizing and selection- Seventh Edition)

2. API 526 (Flanged Steel Pressure Relief Valves-Fifth Edition)

API 14E (Recommended Practice for Design and Installation of Offshore

Production Platform Piping System).

APPENDIX
 APPENDIX 1: AG COMPRESSOR INLET HEADER ENVELOPE

Errosional Velocity Check

15.00

13.00

11.00
Gas Capacity, (MMSCFD)

9.00

7.00

5.00

3.00

1.00

-1.00 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
Liquid Capacity, blpd

Operting Point Inlet header

 APPENDIX 2: GAS COMPRESSOR SYSTEM/OPERATING SUCTION FLOW.

AG Compressor Operating Envelope

SYSTEM CURVE
Flow (Mmscfd)

2 OPERATING CURVE

APPENDIX 3: COMPRESSOR LOAD REQUIREMENT

0
2 3.5
Ps (barg)
 1st Stage Compressor Duty/HP Driver

1200

1000

800
Power, kw

600

400

200

0
3.5 4 4.5 5 5.5 5.9
Flow, Mmscfd

Compressor Duty (Kw) 4: INLET SCRUBBER OPERATING

APPENDIX Driver HP ENVELOPE
 1st Stage Suction Scrubber (V-2701) Operating Envelope

40.00

35.00

30.00
Gas Capacity, MMSCFD

25.00

20.00

15.00

10.00

5.00

0.00
0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
Liquid Capacity, blpd

Operating Point Gas Outlet Nozzle Liquid Outlet Nozzle @1m/s

Inlet Nozzle Vessel degassing Capacity Vessel Gas Capacity

Liquid Outlet Nozzle @1.5m/s LCV Capacity @ 80% Max Relief Capacity
 APPENDIX 5: 2ND STAGE SUCTION SCRUBBER OPERATING ENVELOPE

2nd Stage Suction Scrubber (V-2702) Operating Envelope

40.00

35.00

30.00
Gas Capacity, MMSCFD

25.00

20.00

15.00

10.00

5.00

0.00
0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
Liquid Capacity, blpd

Operating Point Gas Outlet Nozzle Liquid Outlet Nozzle @1m/s

APPENDIX 6: 3RD STAGE SUCTION SCRUBBER OPERATING ENVELOPE
Inlet Nozzle Vessel degassing Capacity Vessel Gas Capacity

Liquid Outlet Nozzle @1.5m/s LCV Capacity @ 80% Max Relief Capacity
 3rd StageSuction Scrubber (V-2703) Operating Envelope
30

25

20
Gas Capacity, Mmscfd

15

10

0
0 10000 20000 30000 40000 50000 60000

Liquid Capacity, Bpd

Vessel Gas Capacity Vessel degassing Capacity Inlet Nozzle

APPENDIX 7: 4TH STAGE SUCTION SCRUBBER OPERATING ENVELOPE
Gas Outlet Nozzle Liquid Outlet Nozzle @1m/s Operating Point

Liquid Outlet Nozzle @1.5m/s LCV Capacity @ 80% Open Max Relief Capacity
 4th Stage Suction Scrubber (V-2704) Operating Envelope
30.00

25.00

20.00
Gas Capacity, Mmscfd

15.00

10.00

5.00

0.00 APPENDIX 8: DISCHARGE SCRUBBER OPERATING ENVELOPE

0 10000 20000 30000 40000 50000 60000
Liquid Capacity, bpd

Vessel Gas Capacity Vessel degassing Capacity Inlet Nozzle

Gas Outlet Nozzle Liquid Outlet Nozzle @1m/s Operating Point
Liquid Outlet Nozzle @1.5m/s LCV Capacity @ 80% Open Max Relief Capacity
 Discharge Scrubber (V-2705) Operating Envelope

18.00

16.00

14.00

12.00
Gas Capacity,Mmscfd

10.00

8.00

6.00

4.00

2.00

0.00 APPENDIX 9: FUEL GAS KO VESSEL OPERATING ENVELOPE

0 10000 20000 30000 40000 50000 60000

Liquid Capacity, Bpd

Vessel Gas Capacity Inlet Nozzle Vessel degassing Capacity Gas Outlet Nozzle

Liquid Outlet Nozzle @1m/s Operating Point Liquid Outlet Nozzle @1.5m/s LCV Capacity @ 80% Open
 Fuel Gas Scrubber (V-4501) Operating Envelope
3.5

2.5
Gas Capacity, (Mmscfd)

1.5

0.5

0
0 10000 20000 30000 40000 50000 60000
Liquid Capacity ,( bpd)

Vessel Gas Capacity Gas Outlet Nozzle Inlet Nozzle Vessel degassing Capacity

Operating Point Vessel degassing Capacity Liquid Outlet Nozzle @1m/s

APPENDIX 10: RELIEF VALVE CAPACITIES

P1 TEMP FLOW Area (Calc)

ITEM PROTECTED SIZE MW Cp/Cv C Z API Selected

Psia deg. R Required (kg/h) Rated (kg/h) sqr inch

27-PSV-
101 K-2701 2J3 234.8 731 3822.7 8,970 17.78 2.5 427.99 0.9932 0.548 1.287

27-PSV-
201 K-2702 1-1/2G3 713.3 738 3822.7 10,702 17.78 2.549 430.38 0.9852 0.180 0.503

27-PSV-
301 K-2703 1E2 1455 753 3813.3 8,602 17.78 2.667 435.95 0.9691 0.087 0.196

27-PSV-
401 K-2704 1-1/2D2 2176 738 3667.4 7,543 17.78 2.861 444.55 0.9417 0.053 0.11

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