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5.0 ALTERNATIVE CONCEPTUAL DESIGN

5.1 Design Criteria & Assumptions

This section provides the design criteria and assumptions made in the selection of Liquid Treatment Facilities
(LTF), and Crude Storage tank farms. The design criteria will also serve as a veritable tool necessary to support
in the development of preliminary and detailed design for all repository process systems. In addition, the
recommended codes and standards required and the policies relating to the LTF and Crude Storage tank
farms are elaborated in subsequent sections.

The key design criteria for the LTF and Crude Storage tank farms are summarized below:

 Design Flow Rates: The LTF and Tank Farm shall be designed to handle a maximum flow capacity with
a design margin in a range of 1.15 minimum to 1.5 maximum for Ekulama 1, Ekulama 2 and Awoba
flowstations. The design shall cater for surging/slugging tendencies of the feed streams, foaming
tendencies of the crude oil and corrosive tendencies of the liquids or gas.
 Efficiency and Quality: The Crude Oil Treatment equipment shall be designed to achieve a dry crude
oil with an export quality of 0.5% maximum Basic Sediments and Water (BS&W).
The Produced Water Treatment Package (PWTP) shall be designed to separate and treat effluent
water for well injection with reduced oil in water concentration of < 10.0 ppm. The PWTP shall also be
designed to achieve a minimum solids removal of 95% > 5microns.
The Separators shall be designed to remove 100% of particles greater than 10 microns as well as
providing sufficient retention time for liquid – liquid disengagement. In addition, vessel internals shall
be selected
 Treating Capabilities: The design shall consider a Crude Oil Treatment equipment with AC/DC fields
for deep dehydration and will be designed to handle a wider range of inlet water in a range 5% - 20%.
The Crude Oil Treatment equipment shall consider composite plate electrodes instead of electrically
conductive materials like normal conventional dehydrators to prevent chain formation and enhance
coalescence.
The design assumes a Crude Oil Treatment equipment with high electrostatic field strength and
coalescing power as well as minimum dosage of demulsifiers.
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 Heat Transfer Mode: The design shall consider a Direct Fired Heater with natural gas burners to lower
crude oil viscosity and for the enhancement of phase separation. Also, treating temperatures shall be
optimised to avoid shrinkage” of the oil, or loss of volume.
The design assumes a heat exchanger shall be used for phase exchange and stabilization of crude oil.
 Fouling Tendencies: A fouling factor shall be applied to heat exchangers to enhance the overall heat
transfer medium The fouling margin to be applied shall be based solely on the expected fouling
propensity of the fluids; it shall not be arbitrarily increased to account for other design margins to be
applied.

 Crude Oil Stabilization: Stabilized Crude Oil reaching the Storage tanks shall have Basic Sediments and
Water (BS&W) in the range 0.2 % minimum to 2 % maximum.

Stabilized Crude Oil en-route the Storage tanks shall be at a thermal condition of Temperature higher
than the Wax Appearance Temperature (WAT) or Cloud Point (CP) of resident Crude Oil but lower
than its autoignition ignition point (AIP). Hence, Crude Oil operating temperature in storage tanks or
en-route tanks shall be in the range of 23°C to 30°C. Samples are required to be retrieved and
analysed for CP and AIP to establish the suitability of the stated temperature range.

Stabilized Crude Oil reaching the storage tanks shall be at a thermal condition of Pressure such that
corresponding absolute (Reid) Vapor Pressure is less than 1 atmosphere i.e. RVP of arriving stabilized
Crude Oil shall be in the range 11.2 to 12.1 PSIA.

Export operations: The export operations shall be based on use of the existing export pumps at
operating pressures not exceeding current practice. The velocity shall be restricted to the range of 3
ft/s – 15 ft/s. The lower limit serves to minimize the deposition of sand and other solids while the
upper limit checks flashing ahead of control valves and minimizes pipeline erosion.

 Site Considerations: The Liquid Treatment facilities and the Crude Storage Tank farms shall be
designed to be readily accessible for maintenance and inspection, including access for a vacuum truck
or other oil- and grit-removal equipment.

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5.1.1 Process Design Codes and Standards

The process design of the LTF and Crude Storage Tank Farm shall comply with the following international
codes and standards as presented in Table 5.01

Table 5.01: Process Design Codes and Standards

CODES DESCRIPTION
ASME B31.8 Gas Distribution and Piping Systems
ASME B31.3 Process Piping
ASME B31.4 Pipelines for Liquid Hydrocarbons and Other Liquids
API 5L Specification for Line Pipe
API 12 L Specification for Vertical and Horizontal Emulsion Treaters
API 12J Specification for Oil and Gas Separators
API 560 Fired Heaters for General Refinery Service
API 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks
API 650 Welded Tanks for Oil Storage
API RP 14C Recommended Practice for Analysis, Design, Installation and Testing of Basic
Surface Safety Systems on Offshore Production Platforms
API RP 14E Recommended Practice for Design and Installation of Offshore Production
Platform Piping Systems
API RP 520 Recommended Practice for the Design and Installation of Pressure Relieving
Systems
API 521 Guide for Pressure Relief and Depressurizing Systems (for information purpose
only)
DEP 31.20.20.31-Gen. Internals for Column
DEP 31.22.05.11-Gen. Gas/Liquid Separators - Type Selection and Design Rules
DEP 31.22.05.12-Gen. Liquid/Liquid and Gas/Liquid/Liquid (Three-Phase) Separators - Type Selection
and Design Rules
DEP 80.45.10.10-Gen. Design of Pressure Relief, Flare and Vent Systems
DEP 80.36.00.30-Gen. Relief Devices - Selection, Sizing and Specification
CODES DESCRIPTION
DEP 31.01.10.10-Gen. Chemical Injection Systems For Upstream Production Facilities
DEP 31.21.01.36-Gen. Heat Exchangers for Packaged Equipment – Design And Fabrication
DEP 20.21.00.31-Gen. Fouling Margins in Tubular Heat Exchanger Design
DEP 31.21.01.12-Gen. Shell and Tube Heat Exchangers; Selection and Application
DEP 31.21.01.30-Gen. Shell and Tube Heat Exchangers (Amendments/Supplements to ISO 16812:2007)
DEP 31.21.01.32-Gen. Plate & Frame Heat Exchangers (Amendments/Supplements to ISO 15547-
1:2005)

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DEP 31.21.70.31-Gen. Air-Cooled Heat Exchangers (Amendments/Supplements to ISO 13706:2005)

DEP 31.21.70.10-Gen. Air-Cooled Heat Exchangers; Selection And Application
DEP 31.24.00.30-Gen. Fired Heaters (Amendments/Supplements To ISO 13705)
DEP 31.21.01.12-Gen. Heat Transfer Fluid Systems
GS EP SAF 227 Safety Rules for Fired Heaters
GIS-46 -010 Specification for Pressure Vessels
GIS-46 -020 Guidance on Industry Standards for Standard Vessel Details

5.1.2 Policies Relating to LTF & Tank Farms

This section is pursuant to the provisions of Part III; section 3.62 (a), 3.6.3.1, and Part IV of the Environmental
Guidelines and Standards for the Petroleum Industry in Nigeria (EGASPIN), 2002. It describes the effluent
limitation in the disposal of oily wastewater in processing facilities and tank farm, water injection criteria, as
well as crude oil dehydration.

The regulatory standard also provides pollution abatement technology, environmental quality control
monitoring procedures, including, the analytical methods for various parameters.

In pursuant to Part IV, section 2.1 of the EGASPIN regulation, the crude oil will undergo deep dehydration processes
based on the selected concept where the anticipated produced formation water as depicted in Figure 4.01 and 4.02 will
be knocked out to achieve Basic Sediments and Water (BS&W) in the range 0.2 % minimum to 2 % maximum.

Table 5.02 and 5.03 present the effluent limitations for the disposal of treated oily wastewater from production
equipment and Crude Storage tank farms according to EGASPIN.

The maximum instantaneous dispersed oil content of produced water discharges will be ≤ 10.0 ppm and with
a minimum solids removal of 95% > 5 microns.

Table 5.02: Effluent Limitations for Inland/Nearshore Oil and Gas Installations for Oily Waste Water

S/N POLLUTANTS OR EFFLUENT COMPLIANCE LIMITS: MAXIMUM FOR ANY UNIT

CHARACTERISICS CONSECUTIVE 30 DAY PERIOD
INLAND NEAR SHORE
1 pH 6.5 - 8.5 6.5 - 8.5
o
2 Temperature 25 30 C
3 Total Hydrocarbon Content (THC) 10 20 mg/l
4 Salinity as Cl 600 2,000 mg/l
5 Turbidity Less than 15% (of NTU
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Receiving Medium)
6 Total Dissolved Solids (TDS) 2,000 5,000 mg/l
7 Total Suspended Solids (TSS) Less than 50 (of mg/l
Receiving Medium
8 COD 10 125 mg/l
9 BOD5 10 125 mg/l
10 Pb+5 0.05 No Limit mg/l
11 Total Iron (Fe) 1.0 No Limit mg/l
12 Cu+2 1.5 - do - mg/l
13 Chromium (Cr+6) Total 0.03 0.5 mg/l
14 Zn+2 1.0 5 mg/l

Table 5.03: Effluent Limitations for Depots

S/N EFFLUENT CHARACTERISICS COMPLIANCE LIMITS: UNIT

MAXIMUM FOR ANY DAY
o
1 Temperature 30 C
2 pH 6.5 – 8.5
3 THC 10 mg/l
4 Total Suspended Solids (TSS) 30 mg/l
5 Total Dissolved Solids (TDS) <2,000 mg/l
6 Sulphide (as H2S) 0.2 mg/l
7 Turbidity 10
8 Chromium (Cr+6) 0.03 mg/l
9 Lead 0.05 mg/l
10 Hg 0.1 mg/l

The following are parties involved in the legal framework for Liquid Treatment Facilities and Crude Storage
Tank Farm operations:
 NEMA, MPR, DPR, OGISP, ICLG together with EGASPIN are responsible for enforcing laws that prevent
pollution.

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 It is a grave offence to pollute the air, soil and water environment - deliberately or accidentally and the
formal consent of NEMA will be required for the control and management of discharges and disposal
of waste under the appropriate regulatory framework. Such consents are granted subject to
conditions and are not issued automatically.
 Certain wastes are defined as “Hazardous Wastes” and are subject to more rigorous controls by
NEMA.

5.2 Alternative Considered but Eliminated from Further Consideration

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