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Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
P RO JE C T P R OP OS AL
FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Table of Contents
1. INTRODUCTION - G2L ENERGY SOLUTIONS ....................................................................... 3
2. FLARING GAS CHALLENGES .................................................................................................... 4
2.1. GOVERNMENT POLICY ........................................................................................................... 5
3. OUR SOLUTION ............................................................................................................................ 5
3.1. PROCESS SCHEMATIC DIAGRAM ....................................................................................... 6
3.2. MAJOR PROCESSES ............................................................................................................... 7
3.2.1. GAS SEPERATION UNIT ..................................................................................................... 8
3.2.2. POWER GENERATION UNIT .............................................................................................. 8
3.2.3. GAS CONDENSATE CONVERTION UNIT ........................................................................ 8
3.2.4. GAS SEPARATION UNIT ..................................................................................................... 8
3.3. LIST OF MAIN PROCESS EQUIPMENT ............................................................................... 8
3.4. PROCESS AUTOMATION SYSTEM .....................................................................................10
3.5. CONTROLS AND INSTRUMENTATION SYSTEMS ...........................................................13
3.6. FACILITY ....................................................................................................................................16
3.7. MAINTENANCE PLANNING AND CONTROL ......................................................................17
3.7.1. PROACTIVE APPROACH ....................................................................................................17
3.7.2. REACTIVE APPROACH .......................................................................................................18
3.7.3. SPARES ..................................................................................................................................19
4. ENVIRONMENTAL BENEFITS ...................................................................................................22
5. PROJECT SCHEDULE ................................................................................................................23
6. COST BENEFIT ANALYSIS ........................................................................................................24
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
1. INTRODUCTION - G2L ENERGY SOLUTIONS
G2L Energy Solutions is a Joint Venture between RUSSELSMITH NIGERIA LIMITED a
leading Integrated Energy Services Company and PUBLIC JOINT STOCK COMPANY “GTL”
(PJSC “GTL”) an Innovative company having serval patents advanced technologies to
producealcohols, alkanes, gasoline, diesel fuel, hydrogen, mineral fertilizers, and other
chemical compounds in a profitable way.
The main mission of this Joint Venture is to provide and install latest technology driven GTL
plants and Gas Turbine Power plants under Nigerian Oil and Gas sector. The major objectives
looking for to achieve are,
Reduction in Flare Gas and the Carbon Footprint of the country.
Production of High-Quality Petroleum Products.
Production of cost Effective and Environment friendly Electric Power.
Development Community and Economy of the Country.
“Reference Patent”
Few of the patent reference are listed below,
2440189 - catalyst and method for producing high-octane gasolines with low content of
benzene and durol
2181622 - plant for homogeneous oxidation of natural gas and method for
homogeneous oxidation of natural gas
2199366 - reactor for homogeneous oxidation of natural gas
2426715 - method and plant for homogenous oxidation of methanic gas
2513917 - device and method for separating gas mixture
2416461 - packed vortex nozzle for heat and mass exchange columns
2487275 - method for compressing gas medium
These solutions will help the Oil & Gas facility Operators to minimize or eliminate the
Government Penalties related to Flaring Gas and add more values to the Organization
Environmental commitmentsand so the Nigerian Government towards Paris Carbon
Emissions Treaty.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
2. FLARING GAS CHALLENGES
The Nigerian National Petroleum Corporation (NNPC) recently disclosed that Nigeria's proven
gas reserve has gone up (as at 2018) to 190 trillion cubic feet (TCF), with unproven gas
reserves of about 600TCF. This data ranked Nigeria in 9th position globally and 1st position in
Africa under the term of proven natural gas reserves. However, the 2nd African position holder,
Algeria producing almost double than Nigeria.
As per Nigeria National Petroleum Corporation (NNPC) 2019 Annual Statistical Bulletin,
Nigeria flared a total of 244.35 billion cubic Feet of gas in the year 2019 which is 8.53% of
produced gas. By considering the exchange rate of N380 to a USD and the Domestic Supply
Obligation (DSO) price of $1.50 per 1,000 Standard Cubic Feet (SCF) of gas, this results to a
loss of N139.28 billion. As per the World Bank’s Global Gas Flaring Reduction Partnership
report, Nigeria is the 7th highest Gas flaring country in the world.
The gas flaring, practicing mainly for economic reasons as the other methods are costlier than
the immediate elimination of the gas, which is less profitable and potentially hazardous
byproduct of the industry. Gas flaring generates toxic pollutants such as sulfur dioxide into the
atmosphere, which can lead to environmental problems such as acid rain, as well as the
generation of greenhouse gases which contribute to global climate change.
When natural gas burning occurs, the effects raise potential environmental and health
hazards. In addition to the noise and light, flaring emits black carbon, methane, and volatile
organic compounds. Black carbon and methane are both powerful climate forcers and black
carbon andVOCs are dangerous air pollutants.
Researchers says black carbon is second only to carbon dioxide in terms of its impact on
global warming. It does this both by absorbing sunlight thereby warming the atmosphere and
by landing on ice and snow and reducing its ability to reflect light. Additionally, black carbon is
a component of fine particulate matter which has negative effects on human health and
contributes to several critical deceases.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
2.1. GOVERNMENT POLICY
By understanding that flared gas could be harnessed to stimulate economic growth, drive
investments, and provide jobs in oil producing communities and indeed for Nigerians through
the utilization of widely available innovative technologies, the Federal Executive Council
(Nigeria’s cabinet) has approved the Nigerian Gas Flare Commercialization Program
(“NGFCP”). This program was launched by the Minister of State for Petroleum Resources
(“Minister”) on December 13, 2016.
The Federal Government of Nigeria (FGN) made the policy that, gas flaring is unacceptable
and the FGN has initiated a number of actions to reaffirm its commitment to ending the
practice of gas flaring in our oil fields. Specifically, the FGN has ratified the Paris Climate
Change Agreement, and is a signatory to the Global Gas Flaring Partnership (GGFR)
principles for global flare-out by 2030 whilst committing to a national flare-out target by year
2020.
The NGFCP is designed as the strategy to implement the policy objectives of the FGN for the
elimination of gas flares with potentially enormous multiplier and development outcomes for
Nigeria. The objective of the NGFCP is to eliminate gas flaring through technically and
commercially sustainable gas utilization projects developed by competent third-party investors
who will be invited to participate in a competitive and transparent process. The
commercialization approach has been considered from legal, technical, economic,
commercial, and developmental standpoints. It is a unique and historic opportunity to attract
major investment in economically viable gas flare capture projects whilst permanently
addressing a 60-year environmental problem in Nigeria.
3. OUR SOLUTION
Based on well-known scientific facts, but not using current processing methods, G2L Energy
Solutions,proposing to provide alternative, highly profitable,and environmentally oriented
methodfor synthesizing the necessary chemicalcompounds from natural and
associatedpetroleum gas.
With the help of technology, both low and high pressure flared gases can be without
conventional Heating and Cooling cyclic processes and apart from this the technology have
the capability to handle any volume of gas; from Two to One Thousand Cubic Meters per
Hour.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
The major advantages are,
Economic efficiency of the processes.
Absence of liquid effluent and harmful emissions which is complying high
environmental standards.
High profitability and the ability to process gas with any composition.
Over 32 types of final products like, Gasoline, Diesel, Alcohols, Alkanes, Mineral
Fertilizers, Hydrogen, Carbo etc.
Complete Automated process
Possibility to build low-capacity processing plants (Modules)
Possibility to increase the production by adding additional modules in respect to oil field
development plan.
Suitable for any difficult climatic or infrastructural conditions.
By considering the market requirements and as part of strategic business plan, we are
planning to develop the Gas to Liquid plant for producing Propane-Butane (Liquid Petroleum
Gas), Gasoline and Diesel. As part of the development plan, we are targeting to complete the
Propane-Butane train and the subsequently the Gasoline train and later the Diesel. This will
help G2L to maintain the easy cash flow.
The annual production volume capacity will be based on the available gas combination and
the volume of supply. The details will be developed in later stages of the project based on the
availability of required data.
3.1. PROCESSSCHEMATIC DIAGRAM
The technology is unique due to its high efficiency, possibility of refining gas containing any
components, including shale gases, with isolating end-product (high-octane petrol, diesel fuel,
methanol, ethanol, and aromatic hydrocarbons), full automation, and high ecological
compatibility, efficiency of process in difficult climate and infrastructural conditions and in low-
output fields.
The schematic diagram below shows the process cycle of the flaring gas before final products.
Due to the modularity of the system, the changes in final products or the volume is very easy
to achieve by adding or bypassing the processes.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
3.2. MAJOR PROCESSES
There are mainly several processes involved in our proved / patented technology, however the
final scope of products and the engineering shall determine the stages of operations
and so the equipment / processes involved.The parameters mentioned in the process
description shall change in final design based on the Gas feed in parameters.
For the processing of associated petroleum gas, the technology was adopted with the
compression of associated gas, its successive cooling and separation from the evolved
condensate and liquefied gas of the PBT grade (technical propane-butane).
The hermetic pistons compressors without oil supply and equipped with frequency converters
shall be used for gas compression.Processing of gas condensate by catalytic conversion with
compression of newly obtained propane / butane fractions to obtain motor fuel (high-octane
gasoline) is envisaged.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
The major equipment composition will be as,
3.2.1. GAS SEPERATION UNIT
• Compression and separation of associated gases with their purification from
water.
• Condensation of gas condensate and its supply to the catalytic conversion unit.
• Supply of liquefied propane / butane gas to the warehouse.
• Supply of fuel gas (combustible component - a mixture of methane and ethane,
inert component - carbon dioxide and nitrogen) for supplying electricity
generation.
3.2.2. POWER GENERATION UNIT
3.2.3. GAS CONDENSATE CONVERTION UNIT
This unit is functioning based on the Zeolite-containing Catalysts,
• The unit is designed to reform gas condensate in order to obtain high-octane
motor fuel, gasoline, propane / butane and a mixture of dry gases (C1 + C2 + H2)
as a by-product.
• The unit includes a catalyst regeneration unit, the service life of the catalysts is 3-
4 years.
• Maintenance personnel of the installation - 2 operators per shift.
3.2.4. GAS SEPARATION UNIT
The unit provides compression and separation of gases after the unit for direct
conversion of gas condensate with the supply of uncondensed gases to the burners
of the furnaces and the supply of liquefied propane / butane gas to the warehouse.
3.3. LIST OF MAIN PROCESS EQUIPMENT
Equipment #
Vessel name Properties of
developed vessel Apparatus
qty.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Equipment #
Vessel name Properties of
developed vessel Apparatus
qty.
K-1 Condensate deethanizer tower D = 1000mm N=20000mm Sieve trays 36 pcs.
1
K-2 Condensate stabilization tower D =1000mm N=13000mm Sieve trays 24 pcs.
1
C-1 “Initial gas-condensate-water” separator (included in compressor station)
1
C-2 Interstage separator (included in compressor station)
1
Р-1 “Initial gas-condensate-water” separator-saturated EG ”
1
Р-2 “Gas-condensate-water” separator D = 1400 mm Lц = 7000mm
1
С-3 Discharge scrubber 1
D-1 Unstable condensate degasser 1
KO-1 Coalescer 1
E-1 Reflux drum of tower K-2 1
ВХ-1* Air cooler after the 1st stage of compressor KG-1/1 (included in compressor station)
type AVG 1
ВХ-2* Air cooler after the 2nd stage of compressor GK-1/2 (included in compressor station)
Type AVG 1
Tb-1,2 Turbulizer 2
ВХ-3* Air condenser of towerK-2 Type AVG 1
Т-1 “Initial gas-dry gas” recuperator llamellar folding 1
Т-2 Heat exchanger for cooling of regenerated ethylene glycol (EG)
coil 1
Т-3 Preheater of unstable condensate before K-1
lamellar folding 1
Т-4 Heat exchanger for cooling of liquefied gas
lamellar folding 1
Т-5 “Initial gas-cold condensate” heat exchanger
lamellar folding 1
Х-1 Freon cooler of gas Shell-and-tube heat exchanger with steam space
1
И-1 Boiler of tower K-1
Shell-and-tube evaporator with steam space
1
И-2 Boiler of tower K-2
Shell-and-tube evaporator with steam space
1
Н-1** Pump for supply of regenerated ethylene glycol (EG)(dosing)
Supply - 174 l/h Pumping pressure-3.5 MPa (abs.) N = 2.2 kW
2
Н-2** Pump for supply of unstable condensate C-2 (dosing)
Supply – 0.42 m3/h Supply head - 186 m N=1,5 kW
2
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Equipment #
Vessel name Properties of
developed vessel Apparatus
qty.
Н-3** Pump for supply of unstable condensate from C-1 (dosing)
Supply – 0.074 m3/h Supply pressure - 2.5 MPa (abs.) N= 2.2 kW
2
Н-4**
Reflux pump of tower K-2 (centrifugal with magnetic coupling)
Supply – 6.24 m3/h Supply head - 83 m N=3 kW
2
КГ-1/1,2
Two–stage compressor by “ARIEL” for compressing of the petroleum gas
Capacity - 305 nm3/min (1st stage) 396 nm3/min (2nd stage) Medium – petroleum gas Psuction – 0.32 MPa (g.); Тsuction – 60 оС Psup. – 3 MPa (g.); N=1900 kW
2
E-2 Drum of industrial heat-transfer medium 1
Н-5** Industrial heat-transfer medium feed pump (centrifugal with magnetic coupling)
Supply – 30.2 m3/h Supply head: 73 m N= 15 kW
2
П-1 Industrial heat-transfer medium heater Q=2000 kW 1
ФХУ-1
Refrigeration plant based on MYCOM compressors
Compression-condensation unit N=3300 kW Refrigeration capacity - 2000 kW Refrigerant – Freon R507 Refrigerant boiling temperature – minus 40 °С
1
БР-1 Ethylene glycol (EG) regeneration unit
Evaporator with heat pipe with electric heating N = 80 kW D = 600mm
Evaporation tower D=250 mm
H = 2500 mm, screen packing.
1
* At calculation of air coolers (AC), air design temperature shall be taken equal to 45 °C.
All AC motors are equipped with frequency converters.
** Feed and supplypressure (supply head) are specified as maximum design ones for all
pumps. Motor of pumps H-2, H-4, H-5 are equipped with frequency converters.
3.4. PROCESS AUTOMATION SYSTEM
All process equipment shall be of modular type with maximum ready-to-use that considerably
reduces the volume of construction and installation activities directly on the site.
In the process of developing the concept for the Process Automation System (PAS), the
following fundamental provisions have been considered:
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
• Monitoring and control of gas processing plant shall be performed based on a single
automated operator's workstation (AOW) with monitors.
• Compressor and refrigeration plants are supplied as part of the package with control and
protection systems; therefore, the main production PAS includes only pressure and
temperature control of gas flows at the compressor plants discharge. To protect
compressor in case of process parameter deviation above the alarm limit values, PAS
controller shall form a discrete command to stop the compressor.
• Control and shut-off valves shall have pneumatic actuators, completed with
electropneumatic actuators.
• To improve reliability of control and energy saving, it is proposed to use frequency
converters to change the performance of electric motors of centrifugal pumps, which will
let to desist from the use of control valves, mainly in level adjustment in tanks.
• In the discharge of all pumps, remotely controlled valves shall be installed and,
accordingly, automatic transfer switch (ATS) for back-up pumps in case of failure of main
ones shall be provided.
• Local operating stations (LOS) shall include only buttons "Start/open", "Stop" and
"Stop/close" for local pumps and motor operated valves control.
• Previously, as a mid-level PAS equipment, intrinsically safe signal input/output modules,
series I.S.1, manufactured by Stahl company, have been accepted, together with i/o
modules for conventional signals, series I-8000 manufactured by ICP-DAS company and
redundant controllers UNO of Advantech company. Subsequent to the results of further
development of the technical means structure, it is possible to select equipment of other
manufacturers with technical parameters not worse than the ones of the mentioned
devices.
Production base for manufacturing of SAW boards and control cabinets shall enable carrying
out a full range of works covering testing, configuration, and adjustment of upper and middle
level subsystems, including their integrated checkout. This allows settling questions of design
and manufacturing of process control points (PCP) in the shortest possible time and with the
best quality, with subsequent delivery of the equipment to the Customer’s site.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Ref. No. Stages of design works Brief Description
1 Development of technical specifications for PAS
The main document, based on which automation systems (full life cycle) are created, objectives are set and the main requirements to PAS (DCS-Distributed Control System and ESDS- Emergency Shut-Down System) are established.
2
Development of the detailed documentation for the Distributed Control System (RSU)
The detailed documentation is necessary for manufacture of DCS, its
reference to the facility and determination of the main requirements to
the project construction parts.
DCS shall be included PAS and designed for plant process control,
including functions of the process interlocks, protections, automatic
regulation and control, collection and processing of information,
provision of the operating personnel with the information and
automated control instruments, as well as information backup
concerning processes and actions of the operating personnel.
DCS will be implemented on Simatic PCS7 software and hardware
facilities manufactured by Siemens. DCS consists of:
1. 1. Control cabinets (CC) with Simatic S7-400 programmable logic
controllers (PLC); 2. Process interface units (PIU) with Simatic DP
input-output system based on ET 200M stations;
3. Automatic work stations and servers with Simatic HMI human-
computer interface system, as well as communication equipment,
power supply units, uninterrupted power supply sources, microclimate
control system. 4. Operating personnel’s panel.
3
Development of the design documentation for theEmergency Shut-Down System (ESDS)
The detailed documentation is necessary for manufacture of ESDS, its
reference to the facility and determination of the main requirements to
the project construction parts. ESDS shall be included to PAS and
shall be designed for provision of safe processes: the system analyzes
the condition of the facility, controls the process parameters, and, if
emergency risks are discovered, transfers the facility into safe
condition.
TheEmergency Shut-Down System will be based on Siemens software
and hardware facilities. The Simatic S7-400H redundant control
system consists of:
1. Control cabinet of the Emergency Shut-Down System (CC of ESDS)
with Simatic S7-400Hredundant programmable logic controller;
2. Process interface units (PIU) with Simatic DP input-output system
based on ET 200M stations with PofiBus DP medium-redundancy
communication line;
3. Immediate and emergency shut-down panel.
4
Development of the design documentation for the automatic fire alarm system and voice-based fire alarm system
The automatic fire alarm system will be implemented on Orion integrated protection system produced by NVP (Scientific and Introduction Enterprise “Bolid” CJSC). The system includes the following:
1. Fire alarm control panels;
2. Automatic and manual fire detectors;
3. Light, sound andsound-and-light alarms;
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Ref. No. Stages of design works Brief Description
4. Redundant power supply sources;
5. Cable products.
5
Development of the detailed documentation for the smoke detection control system and the smoke warning over public address system
The smoke detection control system(SDCS) shall be designed to
control the surrounding atmosphere against leakages and discharges
of vapours and gases. SDCSwill be implemented based on specialized
air pollution sensors and will be connected to ESDS.
6
Development of the detailed documentation for the power supply and electric lighting systems
The power supply and electric lighting system shall include the following:
1. Power supply cabinets with protective devices;
2. Working lighting cabinets with protective devices;
3. Emergency lighting cabinets with protective devices;
4. Security lighting cabinets;
5. Cable products.
7
Development of the detailed documentation for the lightning protection and grounding
The lightning protection and grounding system shall stipulate for:
1. Interception rods;
2. Grounding loop of the plant.
8 Development of the detailed documentation for the engineering safety
The engineering and technical safety shall be inclusive of as follows:
1. Installation of the main fencing along the plant perimeter;
2. Installation of the gates and wickets in the main fencing;
3. Strengthening of the top of the main fencing (anti-climb protection);
4. Strengthening of the lower part of the main fencing (anti-digging protection).
3.5. CONTROLS AND INSTRUMENTATION SYSTEMS
• The equipment shall include local instruments, initial converters (preferable with a
liquid-crystal display), shut-off and control power-driven valves.
• The local instruments shall indicate information for start-up work, at that the
information is not transferred to the process control room.
• The equipment operation shall be controlled from the process control room.
• To perform the measurement, automatic control, signaling and emergency protection
functions, electrical instruments and automated facilities shall be applied.
• The preferable explosion protection type shall be spark-safe circuit “i”, group II,
category 1 as per GOST 30852.0-2002 (MEK (International Electric and Technical
Commission) 60079-0:1998).
• The initial converters of the process parameters shall have a unified analogous and
digital output signal of direct current of 4-20 mА based on HART protocol.
• All temperature converters shall be installed into the equipment operating under
pressure, in protective shells, and shall have a mobile fastening flow nipple.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
• The basic reduced measuring error of the parameter measuring sensors may not
exceed ± 0.5%, in case when the alarm system is actuated – not exceeding ± 1.0%,
of the thermometers and pressure gauges – not exceeding ±1.5 %.
• List of recommended control and measuring equipment and automation facilities is
indicated in Table below,
• Control valves of the regulation loops shall be equipped with diaphragm actuators
(DA) and intellectual electropneumatic actuators. Input and output signals of the
electropneumatic actuator shall be 4-20 mА, explosion protection type – spark-safe
circuit “i”.
• Local control of the power-operated valves designed for emergency shut-off of the
equipment is not required.
• Shut-off pneumatic-drive valves shall be equipped with solenoid-operated valves
(explosion protection type “d”) with control voltage of direct current and terminal
switches (explosion protection type “d”).
• Quick measurement of the flow consumption (number of flows) shall be provided.
• For remote measurement of gas consumption, vortex flow meters shall be applied.
• For remote measurement of liquid consumption, mass-rate flow meters shall be
applied.
• Gas consumption shall be measured in standard m3/h, liquid consumption – in kg/h.
• Liquid level in the vessels shall be controlled by radar level gauges installed, when
applicable, in the bridles, and bypass level detectors.
• Cable inlets in the control and measuring instruments (CAMI) and terminal boxes
shall be blast-tight (explosion protection type “d”), with double sealing of the armored
cable along the outside and inside diameters (without armor) and equipped with “ring”
for the armor grounding.
• Impulse lines to CAMI, drains and vents for sample lines and CAMI (if necessary)
shall be made of stainless-steel pipes O12x1.5, compression fittings with double
sealing of the “cutting ring” type.
• Pneumatic supply lines of shutoff and control valves (SACV) shall be made of
stainless-steel pipes O12x1.5 and O6x1. Provision shall be made for a single input of
the compressed air to the unit with exterior thread G 1/2" (within the boundaries of
the unit, a connector with interior thread G 1/2" will be installed).
• Measurement, alarm, control circuits shall be made of control armored or, if
necessary, screened cable. Maximum number of cores — 37. Cable shall be of “fr”
(flame-retardant) modification.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
• The instruments with current digital output signal (HART protocol) shall be connected
by an armored “twisted pair” cable with the common screening of “fr” modification.
• Provision shall be made for separate wiring (in separate cables and junction boxes)
of the circuits with voltage of up to 42 V, with voltage circuits exceeding 42 V.
• Cables with copper cores of cross section not less than 1.0 mm2 shall be used.
No Description Recommended
1. Temperature (local measurement)
WIKA,
Moscow
2. Temperature (remote measurement) SKB Termopribor,
Korolev
Temperature (remote measurement) of the pump bearings
PG Metran,
Chelyabinsk
3. Pressure (local measurement) WIKA,
Moscow
4. Pressure, pressure drop (remote measurement) PG Metran,
Chelyabinsk
5. Level (local measurement – level detectors) + level (alarm system)
NTPPK "Plazvak", Moscow
6. Level (alarm system) pumps Valcom,
St. Petersburg
7. Level (remote measurement) EmersonProcessManagement,
Moscow
8. Gas consumption measurement (vortex)
EmersonProcessManagement,
Moscow
9. Liquid consumption measurement (mass)
EmersonProcessManagement,
Moscow
10. Electricallyheated instrument boxes with an eyeglass
Rizur NPO (Scientific and Production Association)
Ryazan
11. Impulse lines to control and measuring instruments (CAMI), SACV feed line, CAMI drain and vent lines, fittings and valves.
DK-LOK branch
(supplier of NTA-Prom LLC, Moscow
12. Terminal boxes KORTEM GORELTEX,
St. Petersburg
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
No Description Recommended
13. Ignition system I C P,
Moscow
14. Cable products PODOLSKKABEL,
Podolsk
3.6. FACILITY
• Flare system – can be used available on-site
• Common control room for conducting of process, offloading of gas condensate, PBF;
dispatcher's office — 200 m2
• Administration building — 200 m2, (at the rate of operational staff 25-35 persons),
including:
o Dressing and shower rooms – 50 m2
o Work-rooms– 50 m2
o Laboratory– 30 m2
o Food unit– 30 m2
o Control room, ventilation room – 30 m2
• 3.6. Check passage, guard-house– 30 m2
• Stable condensate tank battery – tanks of 3х200 m3
• Stable condensate pump station — 2 pumps with capacity of 20 m3/h
• Truck terminals of stable condensate – 2 (perhaps, with pumps)
• PBT (propane-butane technical) depot — 10 horizontal tanks per 200 m3each
• PBT pump station
• 2 PBT truck terminals — 2
• Firewater storage tanks (functionally in coincidence with storage of process water
after purification) — 2 underground tanks per 1000 m3 each, or 1000 plus 3000 for
the redundancy of process water.
• Fire pump house (200 ... 500 m3 / h) with networks, without burying is acceptable.
• Interconnections
• Disposal facilities
• Chemical store with ethylene glycol discharge and storage area (in drums of 200 l)
• Instrumentation air compressor unit
• Construction part of associated gas processing unit
• Electrical power supply, transformer substation, independent power generating unit
based on gas generators, total power of 6 MW.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
• Lighting of all the area
• Unit fencing, on-site roads, site improvement (with parking area)
• Potable water supply– imported water
• Process water supply– purified rainwater (it is possible to collect 5-10 thousand cubic
meters of water from rainfall); perhaps, an artesian well.
3.7. MAINTENANCE PLANNING AND CONTROL
Maintenance Planning is the activity to identify and address any possible issues in advance
which will help the Maintenance Engineers to complete the works quickly and effectively.
There are multiple types of maintenance practicing generally in the Oil & Gas industry, which
helps to increase the uptime of the facility and majorly they are coming under following
approaches,
3.7.1. PROACTIVEAPPROACH
Proactive approach works to prevent any reactive maintenance activities by avoiding
surprised shutdowns or breakdowns of the equipment and the processes. Some of
the major maintenance activities shall be considered under the proactive approaches
are,
Preventive Maintenance
Preventive maintenance (PM) is the regular and routine maintenance of
equipment and assets to keep them running and prevent any costly unplanned
downtime from unexpected equipment failure.A good preventive maintenance
plan also involves keeping records of past inspections and the servicing of
equipment.
Predictive Maintenance
Is a proactive maintenance strategy, that uses past inspections and servicing
data from the Preventive maintenance to estimate when the equipment might fail
so that the maintenance work can be scheduled before it occurs.
Condition Based Maintenance
Condition based maintenance performs based on the real time performance and
conditions through the data from sensors and other methods of alarms.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Scheduled Maintenance
Is a scheduled activity on any Equipment or Systems for adjustments,
modifications, replacements of any parts, required as per the OEM requirements
which should be performed on a periodic basis to prevent failure of systems or
equipment or the processes.
Planned Maintenance
Preventive and Scheduled maintenance are a form of Planned maintenance.
However, it starts from identifying from the identification of Resources, Materials,
Tools, and Tasks necessary to work on each maintenance activities. Planned
maintenance have a big role in Proactive Maintenance approaches, as it controls
most of the tabletop activities like, Inspections of data, part ordering, prioritization
etc.
Routine Maintenance
Routine maintenance mainly carried out by the operators / technicians of
operations who doesn’t required any specialized trainings, skills, or equipment to
carried out the tasks. The main activities may be, cleaning, lubricating / greasing,
regular checks of operating parameters and reporting them. The reports or data
generating from Routine maintenance shall be helpful for develop a Planned
Maintenance activity.
3.7.2. REACTIVEAPPROACH
Emergency Maintenance
Corrective Maintenance
All the maintenance plan and schedules shall be generated by considering following
main points,
WHAT
This defines what work needs to be done, what materials, tools, equipment, and
documentation will be required. Most of the time the engineers facing issues due to
lack of the above details. Clear definition on what the work is allows the planner to
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
identify what specific materials will be and may be required to do the work. It also
allows the planner to identify if the task can be completed with basic hand tools or if
specialty tools may be required. Lastly, the planner can identify and provide any
drawings, specifications or other documentation that may be helpful to the craft.
WHY
Defines the reason behind the activity, which provide the context to the maintenance
engineer doing the work, so they understand why they are doing this maintenance
activity.
HOW
This defines HOW the work should be completed. This activity shall be well
documented to help the long-term reliability of the plant. The documentation will help
the individuals to address any startup failures after maintenance activities. This will
also help the organization to use the documentation as a knowledge transfer tool.
PLAN-DO-CHECK-ACT (PDCA)
This process will help the planner to update the planning documentation and to
improve job in future. This will also help the engineers to ensure the safe, effective,
and quality completion of work
Further to this, the following steps shall also use to develop the different Maintenance
Planning and Control process,
Problem Identification
Plan The Task
Schedule The Task
Allocation Of Task
Ensure The Effective Execution of Work
Analyze The Problem
3.7.3. SPARES
We have planned and designed to ensure the in-plant availability of standard spare
parts in addition to the recommended spare parts of the OEM equipment. Some of
the identified key spare parts are listed below,
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Pumps
For all pumps – 1 set of bearings and gland sealing for each pump.
For all electric motors – 1 set of bearings (driven and non-driven) and gland
sealing, if the bearings are lubricated with oil – for each motor.
For plunger pumps– 1 set for each pump: plungers, glands, suction and outlet
valves, pulse dampers.
Connecting drive sleeves for the pumps.
Changeable elements of inlet filters.
Air Fin Coolers
One (1) set of the belts for each of the air fin coolers
Pulleys for the electric engines and shaftsoftheair-fincoolers
Shaftsfor the air fin coolers
1 set of bearings for the shaftsoftheair-fincoolers
Bladesfortheair-fincoolers
Electric engine of the air-fincoolers.
Pneumatic cylinders of the shutters control linkage
Controller of the pneumatic cylinder of the shutters control linkage
Temperature-regulated chamber of the controller of the pneumatic cylinder of the
shutters control linkage
Connecting drive sleeves
Gaskets
1 set of gaskets for each of the heat exchangers
1 set of gaskets for the cooler (chiller)
Gaskets 1", 2", 3", 4", 5", 6", 8", 10", 12", 16" in accordance with the parameters
of the planned GPP (Gas Processing Plant).
Shut-Off and Control Valves
Gland sealing of the shut-off and control valves
Glycol Regeneration Unit
One set of removable elements of fine filters
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
One set of packing for evaporation tower
Freon Cooling Installation
1 set of bearings for each of the electric engines of the compressors and gland
sealing if the bearings are lubricated with oil
1 set of bearings for each of the compressors
Gland sealing of the compressors
Potentiometer (transmission of the feedback (signals) for identification of the
position of the control valve)
Coalescing filters
Removable elements of the filters of the compressor lubricating system
Absorbing filters
Repair kit of the back pressure valve
Electric safety devices of the control panel
Connecting sleeves of the compressors and electric engine
Temperature, pressure and level detectors
For all pumps – 1 set of bearings and gland sealing for each pump
Connecting drive sleeves for the pumps.
Coalescers
Per one (1) set of coalescing elements.
Separators, dividers
Per one (1) set of separating and dividing elements.
Oil Heater
Removable filter elements on fuel gas
Spare parts for burner and ignition devices
Flowmeters
Spare parts for flowmeters
Towers
Per one (1) set of sieve trays for K-1 and K-2 towers.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
4. ENVIRONMENTAL BENEFITS
The proposed technology doesn’t have any hazardous substances / wastes during any stage
of process from beginning to the end.
PROCESS WASTES
The technology doesn’t produce any industrial wastes during the process. The
Catalyst used in production have a service life of 3-4 years. However, the used
Catalysts can be disposed of as ordinary waste or resold since it can be used as a
raw material for road construction.
While using our technology, there is an economically effective transformation of the
thermal energy of dry fuel gas (methane and ethane) into electrical energy without
unnecessary stages of fuel gas preparation. That is, there is no stage for cleaning C1
+ C2 from inert gases CO2 and N2, which means there are no losses during gas
separation (while inert gases serve as a working fluid in gas piston electric
generators).
AIR POLLUTION
With the help of minimized flaring, we shall reduce the Thermal Radiation and Noise
level in the environment which benefit the Eco system and Atmosphere and so the
nearby vegetation and quality of water. The technology will also help to improve the
Air quality of nearby areas by reducing the hazardous gases / materials and increase
in Oxygen level.
This will help the nearby communities to improve their health-related issue like, High
blood pressure, Hearing loss, Respiratory issues, Eye site etc.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
5. PROJECT SCHEDULE
ACTIVITIES ACTIVITIES IN MONTHS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Elaboration of preliminary technical solutions after the detailed study of Available Gas
Development of engineering design documentation
Development of detail design, including:
Preparation of assembly and process flow diagrams, equipment layout
Development of engineereing documentation for plants- manufacturers of packaged and non-standard equipment based on the previously
developed project Steel structures details, as per the detail design
Procurement of standard equipment and
components, in accordance with schedules of purchased items of detail designs.
Manufacture of non-standard equipment and
assemblies
Manufacturing and delivery of steel structures, pipelines and valves in accordance with detailed design specifications for pipelines beyond the
assemblies.
Development of PAS project and procurement of
instrumentation and PAS components.
Author supervision of the equipment fabrication and assembly, construction facility.
QA/QC and Performance check of constructed Equipment.
Shipment of Equipment and installation works
Start-up and commissioning of instrumentation and PAS equipment.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
COST BENEFIT ANALYSIS
Crude Oil Production bbl/Day 10,000
Gas Flaring/ Day 5,000,000
Gas Flaring Penality (in USD) '000 scf $2.00
Discount Rate 7.0%
Base Year 2022
0 1 2 3 4 5 6 7 8 9 10
Discount Factor 1.0000 0.9346 0.8734 0.8163 0.7629 0.7130 0.6663 0.6227 0.5820 0.5439 0.5083
Fiscal year 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032
Costs -$3,650,000 -$3,411,215 $0 $0 $0 $0 $0 $0 $0 $0 $0
Benefits $0 $1,705,607 $3,188,051 $2,979,487 $2,784,568 $2,602,400 $2,432,149 $2,273,037 $2,124,333 $1,985,358 $1,855,475
Net -$3,650,000 -$1,705,607 $3,188,051 $2,979,487 $2,784,568 $2,602,400 $2,432,149 $2,273,037 $2,124,333 $1,985,358 $1,855,475
Cumulative -$3,650,000 -$5,355,607 -$2,167,556 $811,931 $3,596,499 $6,198,898 $8,631,047 $10,904,084 $13,028,417 $15,013,775 $16,869,250
Net Present Value $16,869,250
IRR 39.14%
Year IndexCash Flow
6. COST BENEFIT ANALYSIS
The industry is continuously driving and initiating new approached towards minimizing the operating cost and so the improve the
cashflow and the profitability. The cost benefit analysis mentioned below, will give a picture of economic benefits of the Flaring Gas
supplying field. As the flaring gas data is different on each field, we have assumed certain parameters in YELLOW color, for the initial
study and reference.
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
Project: FLARING GAS COMMERCIALIZATION PROJECT: AUTOMATED GAS TREATMENT
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