DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 2 of 9
TABLE OF CONTENTS
1.0 INTRODUCTION .............................................................................................................. 3
1.1 PROJECT INTRODUCTION ...................................................................................... 3
1.2 DEFINITION .................................................................................................................. 4
1.3 ABBREVIATIONS ........................................................................................................ 4
2.0 PURPOSE OF THIS DOCUMENT ................................................................................. 5
3.0 BASIS AND ASSUMPTIONS .......................................................................................... 5
4.0 METHODOLOGY ............................................................................................................ 6
5.0 STUDY RESULTS ............................................................................................................. 6
5.1 WHPT BLOW DOWN SIMULATION RESULT ....................................................... 6
6.0 PROCESS MINIMUM TEMPERATURE ...................................................................... 7
7.0 COLD VENT MATERIAL SELECTION....................................................................... 7
8.0 DRAIN PIPING MATERIAL SELECTION .................................................................. 7
9.0 LIFT GAS PIPING MATERIAL (DOWNSTREAM OF CHOKE) ............................. 8
10.0 CONCLUSION AND RECOMMENDATION ............................................................... 8
11.0 REFERENCES ................................................................................................................... 8
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 3 of 9
1.0 INTRODUCTION
1.1 PROJECT INTRODUCTION
ZADCO has initiated the Upper Zakum Full Field Development (UZFFD) project
aimed at increasing the target crude oil production rate to 750 MBOPD by the end of
2015 and sustaining this production plateau for at least 25 years.
The Upper Zakum Field will be developed utilizing Artificial Island based drilling and
production centers as new base case developments. The existing surface facilities on
the Satellite Platforms, the Central Complex Platform and the trunk lines will be used
to the maximum extent possible.
The Base Case Development will consist of four islands: South Island (SI), North
Island (NI), Central Island (CI) and West Island (WI) in addition to upgraded satellites
for the north, south and central part of the field. Four existing Wellhead Production
Towers (WHPT’s) PW-32, PC-20, PC-75 and PC-80 will be used to drill new wells
that cannot be reached from the artificial islands with current proven drilling and
completions technology.
Currently production from PW-32 is routed to WSP via PW-38. Production from PC-
20 is routed to CSP via PC-39 and PC-110. Production from PC-80 is routed to CSP
via PC-69 and PC-75 is routed to CSP via PC-63. Due to the capacity constraints of
the existing oil flow lines to handle the additional well fluids production flow from
these platforms, additional new parallel oil pipeline will be installed between PW-32
to PW-38, PC-80 to PC-69 and PC-63 to ZCC. Production from PC-20 is proposed to
be routed to CI. All new producers proposed to be drilled on these WHPT’s will be
gas lift assisted. Lift gas will be supplied to these platforms via new gas pipelines from
CI to PC-20 with a jump-over to PW-32 and from CI to PC-75 with a jump-over to PC-
80. Further a new composite power cables will be installed from CI installed to
WHPTs, PW-32, PC-20, PC-75 and PC-80 to provide electrical energy.
Part I of this Project (P8453B-Part 1) is the hook up of new producers and water
injectors being drilled on WHPT PC-20, PC-80, PC-75 and PW32, including hook up
of the WF Pig traps on PC-20, PW-32, PW-38, PC-63, PC-80 and PC-69.
The scope of this project (P8453B-Part 2) is to install gas lift top side facilities for the
new producers on PW-32, PC-20, PC-75 and PC-80 and upgrade existing topside
facilities to meet the processing requirements for gas lifting of the new producers.
Additionally the new gas pig traps of the new gas lines are to be hooked up on WHPT
PC-20, PW-32, PC-75 & PC-80, including the installation of a jump-over on PC20 and
PC75. Further this project foresees in the conversion of the existing electrical system
on the WHPT to power via the new composite power cable from CI.
Engineers India Limited in New Delhi have completed a FEED study for this Upper
Zakum Facilities New Gas Injection/Gas Lift/Oil Facilities Project Package-B of
ZADCO Project No. P-8453, known as Project P8453B. At present time the gas
injection scope and WAGI scope has been deleted. Detailed design of Part 1 has been
completed by TECHNIP (PC-20, PC-80, PW-32) while PC-75 was done by OSES
due to drilling schedule constraints on PC-75. Accordingly the FEED Package for Part-
2 has been revised and updated by ZADCO Engineering Department to prepare for
EPC of Part 2.
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 4 of 9
1.2 DEFINITION
Company : Zakum Development Company (ZADCO)
Engineer : Engineers India Limited (EIL)
Project : New Gas Injection/Gas Lift/Oil Facilities Project Package-B
1.3 ABBREVIATIONS
The following abbreviations are relevant to this project:
ADMA-OPCO Abu Dhabi Marine Operating Company
ADNOC Abu Dhabi National Oil Company
BOPD Barrels of Oil Per Day
BWPD Barrels of Water Per Day
CC Central Complex of Upper Zakum
CI Central Island
CSP Central Separation Plant, located at CC
DOP Design Office Practice
FEED Front-End Engineering Design
GI Gas Injection
GIP Gas Injection Platform located at ZWSC
GOR Gas to Oil Ratio (scf/stb)
HC Hydrocarbon
HP High Pressure
LP Low Pressure
MBOPD Thousand Barrel of Oil per day
MMSCF Millions of Standard Cubic Feet
MPFM Multi Phase Flow Meter
NI North Island
NSP North Satellite Platform
PHSER Project Health Safety Environment Review
ppm Parts Per Million
ptb Pounds Per Thousand Barrels
SI South Island
SOW Scope Of Work
SSP South Satellite Platform
TEG Thermo Electric Generator
UZ Upper Zakum
UZFFD Upper Zakum Full Field Development
WAG Water Alternate Gas Injection
WC Water Cut
WI Water Injection
WSP West Satellite Platform
WHPT Well Head Production Tower
ZADCO Zakum Development Company
ZCC ZADCO Central Complex
ZR Zirku Island, where ZADCO operates process facilities and stores
oil for export
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 5 of 9
ZWSC Zakum West Super Complex offshore platform owned and
operated by ADMA
2.0 PURPOSE OF THIS DOCUMENT
The purpose of this document is to determine the minimum temperature expected during
depressurization and during startup of gas lift topside piping. This temperature shall be used
in selecting the materials for equipments, piping and instrumentation. Depressurization
calculation was performed using the HYSYS version 8.0 depressurization utility. The
objectives of this study are as follows:
Determine the expected minimum temperature during depressurization of the gas
injection topside process systems.
Determine the expected minimum temperature during start-ups.
Recommend materials of construction for wellhead platform facilities such as Gas lift
manifold, gas lift line, depressurization line.
3.0 BASIS AND ASSUMPTIONS
The minimum temperature is determined by the lowest of following criteria:
1. Minimum operating temperature
2. Minimum ambient temperature
3. Minimum temperature resulting from depressurization
For the purpose of this report the vessels and pipe work temperatures upstream of the
depressurization valve are assumed to reach the minimum ‘Vessel Wall Temperature’,
as calculated by HYSYS.
Minimum temperature allowed in topside carbon steel piping is 16ºF.
The hold-up volume is considered from Riser Shut-down valve to shut down valve of
respective WHPT flow strings. Two cases are considered for the study with 4m3 and
1m3 volume. This needs to be finalized based on pipe routing for individual platforms
namely PC-20, PC-75,PC-80 and PW-32.
The depressurization study has been performed for various cases in Wellhead Vent
and drain study (ZADCO doc. no. P8453B-SR-000-F-0011).
The Case-II normal operating winter case and Case-III isochoric settle-out case
results has been utilized for this study.
For Case-III isochoric settle-out case: Adiabatic depressuring from initial
conditions of ambient temperature (48°F) and the corresponding Isochoric
pressure (constant volume cooling from shut-in at operating conditions). This case
will determine the minimum possible temperature downstream of
depressurization facility.
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 6 of 9
4.0 METHODOLOGY
Each isolatable hydrocarbon system with depressurization provisions (on the topsides) was
considered as a possible case for low temperature. The minimum temperatures resultant from
depressurization is reliant upon gas/liquid composition, pressure at beginning of
depressurization, ratio of volume to metal mass, liquid volume (& wetted area) and isentropic
efficiency.
The detailed methodology for depressurization has been already described in Wellhead Vent
and drain study (ZADCO doc. no. P8453B-SR-000-F-0011).
5.0 STUDY RESULTS
5.1 WHPT BLOW DOWN SIMULATION RESULT
Case –II: Winter Condition
CI gas Composition is considered for PC20, PW-32, PC-75 & PC-80
The hold-up volume of 4 m3 is considered for the depressurization. Actual volume of
each of the platform for top sides has to be considered for calculation based on final
pipe routing.
The minimum temperature upstream of valve -106 ºF and minimum temperature
downstream of valve 32 ºF. The peak vapor flow during depressurization is 1867
lb/hr.
Case –III: Winter Condition – Isochoric Settle out Conditions
CI gas Composition is considered for PC20, PW-32, PC-75 & PC-80
The hold-up volume of 4 m3 is considered for the depressurization. Actual volume of
each of the platform for top sides has to be considered for calculation based on final
pipe routing.
The minimum temperature upstream of valve -113 ºF and minimum temperature
downstream of valve 17 ºF. The peak vapor flow during depressurization is 1784
lb/hr
From above, the minimum temperature in vent system is -113 ºF. Since the vent
system design temperature is -178ºF, this startup depressurization condition will be
well within the design limit.
The depressurization rate of top sides is checked for 4m3, 1m3 and to be confirmed
based on final piping routing for individual platform. The rates are controlled to ensure
single step depressurization. However, for GI/GL pig launcher / receiver the volume /
metal mass is very less and depressurization is to be done is steps, the operator should
ensure that the upstream temperature of globe valve shall not fall below 16ºF.
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 7 of 9
6.0 PROCESS MINIMUM TEMPERATURE
The minimum temperature as predicted by HYSYS depressurization utility and
recommended materials are given below:
System Fluid Minimum Temperature, ºF Design Condition &
Process Section Isochoric Settle-out Normal Operating Recommended
Case Case Material
+16ºF @ Design
Pressure (16ºF is
based on pipeline
Gas Lift Manifold +16 +16 MOC Minimum
Temperature
Constraint) &
Carbon Steel
Notes:
1. No margin has been added to the above recommended minimum design temperatures.
2. It is recommended that immediately after depressurization, platform must not be re-
pressurized if the metal temperature is colder than ambient. This is because low
temperature occurs during re-pressurization due to gas expansion and if any leak is
identified during re-pressurization, then the system should be once again depressurized
immediately, which leads to further reduction of temperature (i.e. much lower than 16ºF).
7.0 COLD VENT MATERIAL SELECTION
The selection of the cold vent material for each gas lift platform is based on the minimum
temperature at the depressurization valve outlet.
Minimum Temperature @ Design Condition &
Process Section
Valve Outlet, ºF Recommended Material
Cold Vent System (PW-32,
PC-20, PC-75 & PC-80) -178ºF @ Design Pressure &
-106 to -113
-Normal Operating Winter SS316 L
Case and Isochoric case
8.0 DRAIN PIPING MATERIAL SELECTION
The selection of the drain piping material for each process area is based on the operating
philosophy and procedure that the system will be depressurized first and then will be allowed
to be heated by ambient temperature above 16°F. The drains are routed to the existing sump
tank which is CS metallurgy.
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 8 of 9
9.0 LIFT GAS PIPING MATERIAL (DOWNSTREAM OF CHOKE)
Following conditions were considered to be the governing condition at gas lift flow line top
sides.
The maximum gas arrival pressure 1850 psig.
The minimum gas arrival temperature envisaged at any wellhead platform is considered
to be same as minimum sea bed temperature which is 18ºC (64.4ºF).
Due to pressure reduction across start up globe valve, choke valve, the minimum
temperature downstream of choke valve is lower due to flashing. The pressure will be
controlled by the 2” bypass globe valve on start-up line and flow will be controlled by the
choke valve. Though the temperature during normal restart is within CS limits, low
temperature carbon steel has been specified for all gas lift line downstream of choke
based on COMPANY recommendation.
10.0 CONCLUSION AND RECOMMENDATION
The outcome of this study are:
The manual depressurization flow of the wellhead platform is adjusted to ensure that
temperature is above 16ºF. Rates are calculated for 4m3 and 1m3 of sensitivity cases
and actual volume is to be finalized based on the final pipe routing for individual
platforms. For the GI/GL pig launcher / receiver the depressurization has to done in
steps, the fluid temperature is to be allowed to increase by ambient heat before
resuming and completing the depressurization.
Upstream of depressurization valve shall be CS as minimum temperature during
depressurization is limited to 16ºF. SS is recommended for downstream of
Depressurization valve due to minimum temperature estimated downstream of valve
depressurization is -113ºF.
11.0 REFERENCES
1. Basis of Design (Process), ZADCO Document No.P-8453B-BD-000-F-0002.
2. P-8453 Package-B, Gas injection/Gas Lift/Oil facilities feed Services Appendix-A :
Project Description & Statement of Requirement
3. P-8453 Package-B, Gas injection/gas Lift/oil facilities feed Services Appendix-B:
Scope of Services
4. Wellhead Vent and drain study (ZADCO doc. no. P8453B-SR-000-F-0011).
5. Minimum Temperature Study- Contract No. CTE FE0502 10, Project P8276.
6. Vent & Drain philosophy, ZADCO doc. No. P8453B-BD-000-F-0008.
7. P8453B Piping plot plan detail.
8. P8383 Piping plot plan detail.
9. Process Flow Diagram WHPT PW-32, Dwg. No. P8453B-A1-032-F-0009.
10. Process Flow Diagram WHPT PC-20, Dwg. No. P8453B-A1-020-F-0009.
11. Process Flow Diagram WHPT PC-75, Dwg. No. P8453B-A1-075-F-0009.
12. Process Flow Diagram WHPT PC-80, Dwg. No. P8453B-A1-080-F-0005.
13. Heat & Material Balance WHPT PW-32, Dwg. No. P8453B-A1-032-F-0010.
Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
DOCUMENT No.
UPPER ZAKUM FACILITIES ZADCO:
NEW GAS INJECTION/GAS LIFT/OIL P8453B-SR-000-F-0010
EIL: A283-05-45-SR-1002
FACILITIES PROJECT PACKAGE-B REV D
Page 9 of 9
14. Heat & Material Balance WHPT PC-20, Dwg. No. P8453B-A1-020-F-0010.
15. Heat & Material Balance WHPT PC-75, Dwg. No. P8453B-A1-075-F-0010.
16. Heat & Material Balance WHPT PC-80, Dwg. No. P8453B-A1-080-F-0006.
17. Sizing, Selection and Installation of Pressure Relieving Devices In Refineries - API
RP 520, Seventh Edition, Jan 2000.
18. Guide for Pressure Relieving and Depressuring Systems - API RP 521, Fifth Edition,
January 2007.
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Format No. EIL 1641-1924 Rev. 1 MINIMUM TEMPERATURE STUDY
