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KGP-1-6100-007-A1-4-O
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Table of contents
KGP-1-6100-007-A1-4-O
page
1
1.1
1.2
Introduction
Background
Location Sketch
5
5
5
Objective
Process Description
Basis
Methodology
References
Appendix- I : Phase Envelope & Hydrate formation Table for Kauther Gas
Appendix- II : Phase Envelope & Hydrate formation Table for Fakhr Gas
9
10
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Revision O
page 4 of 10
KGP-1-6100-007-A1-4-O
ABBREVIATIONS
ADP
CGR
EPC
FGS
KGP
MMSCMD
NPV
PDO
RMS
SP
SR CPP
T&P
UTC
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1
1.1
Introduction
Background
The 2003 ADP Base Case shows that an additional gas source is required to meet the demands of new
industries (methanol and ammonia plants) planned for the Sohar area. The Kauther Cluster reservoirs
have been selected (as the next biggest undeveloped reserves with the highest NPV and one of the
lowest UTCs) to meet this demand. Kauther cluster comprises the Kauther and Fakhr reservoirs. Due
to the higher CGR of Fakhr over Kauther, Fakhr will be produced preferentially with Kauther making up
the balance.
Government Gas is developing the Kauther field facilities to provide both condensate and gas for
export. KGP will be designed to process 20 MMSCMD (wet) gas. The Kauther development comprises
four elements: the Gas Plant, the gas and condensate export pipelines, the field gathering system and
power supply facilities.
1.2
Location Sketch
Objective
To check possibility for hydrate formation in the FGS using Hysys simulator and suggest preventive
action.
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Process Description
The Kauther FGS will comprise of flow lines from 23 wells, 3 remote manifold stations and 3 bulk lines
from the RMS to the KGP inlet manifold. Out of the total 23 wells, 4 wells are part of the Fakhr field and
19 wells are part of the Kauther Field. Depending on their location in the field, the wells tie into one of
the three remote manifold stations, midway of the bulk lines or directly to the KGP inlet manifold. In
KGP, there will be two manifolds each having equal numbers of well tie-in. Double block and bleed
valve for each bulk line, test line and direct flow line on KGP manifold will be provided by KGP
contractor. A schematic of the Kauther FGS is given in Figure 1.
The facilities will be designed for a maximum plant capacity of 20 MMSCMD of wet gas. The test
headers will be designed to handle 1.5 MMSCMD.
The Kauther FGS and the flow lines will be adequately sized to meet the future depletion scenarios.
First stage depletion is expected in year 2010 when the operating pressure reduces to 50 bara and the
second stage depletion is expected in year 2012 when the operating pressure will reduce to 20 bara.
Figure 1 : Schematic of the Kauther Field Gathering System
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Basis
Hysys models prepared for simulation study for 100 bara operation, 50 bara operation and 20 bara
operation were used to do hydrate formation study. The pressure and temperature at wellhead and at
KGP inlet were established based on the hydraulic calculation carried out in the Pipesim simulation.
Table-1
Cases
Operation
Wellhead Operating
year
Pressure
bara
2009
II
Temperature
C
Pressure
bara
Temperature
o
C
101-106
120
100
114.7
2010
50-70
120
50
108.6
III
2012
20-50
120
20
96.5
I-A
2009
101-106
70
(Win. Gr. Temp.)
100
67
Max./Min
: 130oC / 5oC
Ground Temperature
Summer
: 30oC
Winter
: 22oC
Following locations were reviewed for potential hydrate formation in the FGS during winter :
1) Point A : Downstream of the vent line at Wellhead / RMS.
2) Point B : Downstream of the relief valve at Wellhead.
3) Point C : Flow line/ Bulk line/ Test line blocked in pressurised condition.
Methodology
Case-I
In the Hysys model for year 2009-100 bara operation, the stream coming from the wellhead was
selected. This is the worst case from the hydrate formation point of view since hydrate formation
temperature decreases with the decrease in the operating pressure. By using utilities function in Hysys
a phase envelope (Refer Appendix-I & II) was generated showing pressure and temperature
relationship of the selected stream. Bubble point (Bpt), Dew point (Dewpt), Critical point (CritPt), and
Hydrate formation curve (Hyd) data is available from the phase envelope. It was found from the
envelope that hydrate formation could start below 19.5 oC for 100 bara operation. Refer Table-2.
Case-II :
The composition of the depletion case is considered same as 100 bara operation. Similar to case-I the
Hysys Model for year 2010 -50 bara operation found that hydrate formation could start below 15.1 oC at
working pressure. Refer Table-2.
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Case-III :
Similar to case-II the Hysys Model for year 2012 -20 bara operation found that hydrate formation could
start below 8.7oC at working pressure. Refer Table-2.
Case
Year
2009
II
2010
III
2012
Fluid
Operating
Condition
Pressure
bara
Temp.
degC
108
120
19.2
19.5
50
120
14.7
15.1
20
120
8.4
8.7
Natural
Gas
Natural
Gas
Natural
Gas
From the above results, hydrate formation in the FGS is not possible during the normal operation.
Following are the situations where the low temperatures could be seen in the FGS:
1) Start-up after winter shut down.
2) Depressurization in winter after a long shut down.
Hence, it should be ensured that during the plant shutdown in winter, the FGS should be depressurized
quickly without allowing it to reach the equilibrium with the low ambient temperatures otherwise there is
a possibility of hydrate formation in the downstream of depressurization valve.
However, provision for methanol injection has been made on each wellhead upstream of the choke
valve. Methanol will be injected as required by operational considerations.
It is recommended that a portable methanol injection pump (air driven) and tank be procured under the
EPC contract.
References
1)
Process Design Basis Report T & P Document No. 80166 3111001 (Latest Revision).
2)
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Appendix- I : Phase Envelope & Hydrate formation Table for Kauther Gas
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Appendix- II : Phase Envelope & Hydrate formation Table for Fakhr Gas