Copyright of Shell Global Solutions International B.V.

Design of Compressor Suction

Scrubbers
Or
Dont wreck the expensive compressor with cheap
scrubbers or with inadequate engineering
TEKNA-Conference
Norway, 26-27 September 2012
Hans Nooijen, GSNL-PTD/TRD Paul Clinton, GSNL-PTU/EKUW
Principal Technologist Distillation Principal Concept Engineer
Copyright of Shell Global Solutions International B.V.
DEFINITIONS AND CAUTIONARY NOTE
2
Resources: Our use of the term resources in this announcement includes quantities of oil and gas not yet classified as Securities and Exchange Commission of the United
States ("SEC") proved oil and gas reserves or SEC proven mining reserves. Resources are consistent with the Society of Petroleum Engineers 2P and 2C definitions.

The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate entities. In this announcement "Shell", "Shell Group" and "Royal Dutch
Shell" are sometimes used for convenience where references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words "we", "us" and "our"
are also used to refer to subsidiaries in general or to those who work for them. These expressions are also used where no useful purpose is served by identifying the
particular company or companies. "Subsidiaries", "Shell subsidiaries" and "Shell companies" as used in this announcement refer to companies in which Shell either directly
or indirectly has control, by having either a majority of the voting rights or the right to exercise a controlling influence. The companies in which Shell has significant influence
but not control are referred to as "associated companies" or "associates" and companies in which Shell has joint control are referred to as "jointly controlled entities". In this
announcement, associates and jointly controlled entities are also referred to as "equity-accounted investments". The term "Shell interest" is used for convenience to indicate
the direct and/or indirect (for example, through our 23 per cent. shareholding in Woodside Petroleum Ltd.) ownership interest held by Shell in a venture, partnership or
company, after exclusion of all third-party interest.

This announcement contains forward looking statements concerning the financial condition, results of operations and businesses of Shell and the Shell Group. All
statements other than statements of historical fact are, or may be deemed to be, forward-looking statements. Forward-looking statements are statements of future
expectations that are based on management's current expectations and assumptions and involve known and unknown risks and uncertainties that could cause actual
results, performance or events to differ materially from those expressed or implied in these statements. Forward-looking statements include, among other things, statements
concerning the potential exposure of Shell and the Shell Group to market risks and statements expressing managements expectations, beliefs, estimates, forecasts,
projections and assumptions. These forward looking statements are identified by their use of terms and phrases such as "anticipate", "believe", "could", "estimate",
"expect", "goals", "intend", "may", "objectives", "outlook", "plan", "probably", "project", "risks", "seek", "should", "target", "will" and similar terms and phrases. There are a
number of factors that could affect the future operations of Shell and the Shell Group and could cause those results to differ materially from those expressed in the forward
looking statements included in this announcement, including (without limitation): (a) price fluctuations in crude oil and natural gas; (b) changes in demand for Shell's
products; (c) currency fluctuations; (d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g) environmental and
physical risks; (h) risks associated with the identification of suitable potential acquisition properties and targets, and successful negotiation and completion of such
transactions; (i) the risk of doing business in developing countries and countries subject to international sanctions; (j) legislative, fiscal and regulatory developments
including regulatory measures addressing climate change; (k) economic and financial market conditions in various countries and regions; (l) political risks, including the risks
of expropriation and renegotiation of the terms of contracts with governmental entities, delays or advancements in the approval of projects and delays in the reimbursement
for shared costs; and (m) changes in trading conditions. All forward looking statements contained in this announcement are expressly qualified in their entirety by the
cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward looking statements. Additional factors that may affect
future results are contained in Shell's 20-F for the year ended 31 December 2011 (available at www.shell.com/investor and www.sec.gov ). These factors also should be
considered by the reader. Each forward looking statement speaks only as of the date of this announcement, 22 February 2012. Neither Shell nor any of its subsidiaries nor
the Shell Group undertake any obligation to publicly update or revise any forward looking statement as a result of new information, future events or other information. In
light of these risks, results could differ materially from those stated, implied or inferred from the forward looking statements contained in this announcement.

Shell may have used certain terms, such as resources, in this announcement that the SEC strictly prohibits Shell from including in its filings with the SEC. U.S. investors
are urged to consider closely the disclosure in Shell's Form 20-F, File No 1-32575, available on the SEC website www.sec.gov. You can also obtain these forms from the
SEC by calling 1-800-SEC-0330.

Copyright of Shell Global Solutions International B.V.
CONTENTS
1. What is the problem?
2. Its an old problem and its an ongoing problem
3. Why do we get it wrong?
4. Examples of getting it wrong.
5. How should we get it right?
10/2/2012 3
Copyright of Shell Global Solutions International B.V.
WHATS THE PROBLEM?
1
4 10/2/2012
Copyright of Shell Global Solutions International B.V.
WHAT IS THE PROBLEM?
Inadequate separation upstream of compressors results in:
Liquids entering the compressor
Dissolved and entrained solids entering the compressor

Effect on the compressor:
Erosion
Deposition of solids

Eventual consequences:
Reduction of compression efficiency = loss of performance
Rotor imbalance - more unscheduled maintenance
Possible catastrophic failure
5 10/2/2012
Copyright of Shell Global Solutions International B.V.
ITS:
An old problem
A current problem
An ongoing problem

2
6 10/2/2012
Copyright of Shell Global Solutions International B.V.
Case 1 Lift Gas Compressors Performance Check K-614

The second stage discharge pressure is higher than
expected. The high pressure trip has been reached
and the machine keeps tripping.

The problem has been getting worse and it is
suspected that carry-over is fouling the machine up.
This would have its greatest effect in the third stage
where the clearances are smaller.
27 May 1984
COMPRESSOR FOULING - ITS AN OLD PROBLEM
10/2/2012 7
Copyright of Shell Global Solutions International B.V.
The liquid being drained from the casing drain resembled heavy crude
rather than condensate.
GS.06.50099 Case 1 Visit Report : COMPRI & Smart Fields Scouting Study
CASE 1 IN 2006
10/2/2012 8
Copyright of Shell Global Solutions International B.V.
CASE 2
10/2/2012 9
Copyright of Shell Global Solutions International B.V.
Salt
deposits
CASE 3
10/2/2012 10
Copyright of Shell Global Solutions International B.V.
CASE 4 - FOULED DIFFUSER
10/2/2012 11
Copyright of Shell Global Solutions International B.V.
CASE 5 - 1
ST
STAGE COMPRESSOR INLET EYE
10/2/2012 12
Copyright of Shell Global Solutions International B.V.
CASE 6 COMPRESSOR - EROSION
10/2/2012 13
Copyright of Shell Global Solutions International B.V.
When machine
was opened,
these pools of
liquid were found
in it.
CASE 7 CATASTROPHIC FAILURE
10/2/2012 14
Copyright of Shell Global Solutions International B.V.
CASE 7 - PIECE BROKEN OFF IMPELLER
10/2/2012 15
Copyright of Shell Global Solutions International B.V.
CASE 7 - BROKEN SEAL
10/2/2012 16
Copyright of Shell Global Solutions International B.V.
WHY DO WE GET IT WRONG?
3
17 10/2/2012
Copyright of Shell Global Solutions International B.V.
WHY DO WE GET IT WRONG?
Ignorance - not thinking about our design and not understanding
what is happening in our own process
Not following established good practice
Delegating design responsibility
Lack of attention to detail
No close supervision of contractors
Package unit & vendor guarantee mentality
Concept of Industry standard
Attempt to save money
10/2/2012 18
Copyright of Shell Global Solutions International B.V.
HOW DOES A COMPRESSOR SUCTION SCRUBBER
WORK?
Vessel
Provides larger flow area to
reduce flow velocity
For gas dominated two phase
flow, vertical vessel makes best
use of available area
If high proportion of liquid, need
pre-separation
Control volume for separated
liquid
19 10/2/2012
Inlet nozzle & pipe
Avoids severe maldistribution of
two phase flow across pipe area
Provides non slugging flow
regime
If mist flow be careful - if very
small droplet size, difficult to
separate
Inlet device
Makes coarse gas/liquid
separation
Distributes gas flow across vessel
area
Avoids re-entrainment of droplets
Demisting internals
Remove liquids by various means
Merge small droplets into bigger
droplets
Catch the droplets (cyclones, flow
direction change, etc
Return removed liquid to bottom
of vessel
Outlet nozzle & pipe
Avoids channeling of flow in the
demister
Copyright of Shell Global Solutions International B.V.
What is wrong with this PFS?
(what is missing?)
wells Flowlines
(5 - 10 km long)
manifold Production separator
compressor
A clue:
Now the second
stage is shown
Suction
scrubber was
missing
Production separators are only
bulk separators, just like slug
catchers.
UNDERSTANDING BEGINS AT THE PFS
20 10/2/2012
Copyright of Shell Global Solutions International B.V.
PEFS
Production
separator
What instruction is missing from these
PEFSs?
To compressor
PEFS
Compression
From separator
To second
compression train,
see PEFS xyz
Slope, do
not pocket
Slope, do
not pocket
Slope, do
not pocket
Instructions to avoid slug formation!
UNDERSTANDING CONTINUES TO PEFS
10/2/2012 21
Copyright of Shell Global Solutions International B.V. 10/2/2012 22
RUNNING PIPING TO COMPRESSORS - PLAN VIEW

Piping dept dont know about slugs and the
capabilities of your separators.
If you dont instruct otherwise they will run the
pipes in the most convenient way:
At grade
Underground
Distance can be > 100 m
Well flowlines
Compression train
Compression train
Copyright of Shell Global Solutions International B.V.
RUNNING PIPING TO COMPRESSORS - ELEVATION
VIEW
10/2/2012 23
Suction scrubbers are not
slugcatchers.
When a slug hits the suction scrubber,
a significant proportion will leave in the
gas and enter the compressor.
Production
separator
S
u
c
t
i
o
n

s
c
r
u
b
b
e
r

Worst case is starting another
compressor. The equilibrium hold up
changes and a huge slug can be
generated.
High carryover to compressor
LZHH may be reached on running
machines - which will trip.
This gas pipe is now similar to a two phase
cross country pipeline. And it also has
slugs:
Terrain induced
Flow rate induced
A half full 100m long 30 inch pipe holds 7
m
3
of liquid!

Copyright of Shell Global Solutions International B.V.
LZHH
LZLL
Clearance for
access
Range for
control
By the time you have
engineered the drain pot,
how high must the pipe be
elevated?
Definitely higher than it
used to be!
I CAN SOLVE THAT WITH A DRAIN POT!
10/2/2012 24
Copyright of Shell Global Solutions International B.V.
Liquid removal by dip tube or
occasional blowdown are
desperate measures for
constructed plant. They should not
be engineered into a new design.
IF YOU CANNOT ELIMINATE SLUGS, ONLY PROPER
SOLUTION IS A SLUGCATCHER
10/2/2012 25
To suction scrubber
slugcatcher
Long pipe
The slugcatcher will eliminate slugs.

Underground slugcatchers are nice for the
hydraulics, but very difficult for
maintenance and safety. (dont do it)

Dont forget that the compressor will still
require a suction scrubber.
Copyright of Shell Global Solutions International B.V.
Slope, do
not pocket
Note 1. No bends in horizontal plane, valves or swages allowed within 10 pipe diameters of inlet nozzle
Note 2. No bends in horizontal plane, valves or swages allowed within 2 pipe diameters of outlet nozzle
Note 1
Note 2
Inlet nozzle v
2

requirement usually
needs larger pipe size.
Outlet nozzle v
2

requirement usually
needs larger pipe
size.
Inlet nozzle
straight length
requirement.
Outlet nozzle
straight length
requirement.
SUCTION SCRUBBER INLET & OUTLET PIPING
10/2/2012 26
Copyright of Shell Global Solutions International B.V.
DEVIATION FROM SEPARATOR DEP
10/2/2012 27
Vendor Special
Exciting new technology
Smaller vessel
Cheaper!
CFD based design
Great list of installed units
(but have you spoken to
them?)
DEP Separator
Established technology
Based on many actual
field tests across Shell
Group
Deviation Control
Not applying the DEP requires approval to deviate from Shell practice.
You are not authorized to make this decision.
Why Gamble?
Taking a gamble on a cheaper scrubber is just not worth the risk of compressor damage.
Copyright of Shell Global Solutions International B.V.
Please remember that all these examples were engineered -
by engineers - it wasnt an accident.

EXAMPLES OF GETTING IT WRONG

4
28 10/2/2012
Copyright of Shell Global Solutions International B.V.
The root cause failure report for K 0611 highlighted (utilizing thermo-graphic photos)
that the liquid suction header for the inlet scrubber was half filled with liquids (low
section of the header). This is the suction header to inlet scrubber V-0610.
CASE 1 IN 2006
10/2/2012 29
Copyright of Shell Global Solutions International B.V.
Long underground lines from flow
station
CASE 8
10/2/2012 30
Copyright of Shell Global Solutions International B.V.
What basis is there for believing that
this proprietary separator will work?
CASE 1 K-614 SCRUBBER - VESSEL DATA SHEET
10/2/2012 31
Copyright of Shell Global Solutions International B.V.
Dresser stated that they were
unable to comply with 24
manway requirements.

Customer (x) agreed for
vessels with no internals.
CASE 1 K-614 SCRUBBER - IT GETS EVEN WORSE
10/2/2012 32
Copyright of Shell Global Solutions International B.V.
PROPRIETARY SEPARATOR CASE 9
10/2/2012 33
Flow evenly
distributed
across vane
pack?
Re-entrainment
of droplets?
Channelling
through vane
pack?
Inlet 12
Outlet 12
Vessel ID
= 750 mm
Copyright of Shell Global Solutions International B.V.
In September 2003 severe rotor damage of the Export compressor K-83502
occurred.
Liquid carryover from the suction scrubber vessel V-83502 was identified as a
possible cause of failure.
To quantify the level of liquid carryover and to determine the separation efficiency of
the scrubber V-83502, a dedicated isokinetic sampling campaign was carried out by
Shell Global Solution (SGSi-OGRD) over the period 10 to 12 October 2004.
The vendor guarantee specification for liquid in the off gas from this scrubber is
< 13 litres/MMsm3 (0.1 US gal/MMsft3). This translates to an actual liquid
concentration
of < 10 ppmw in the scrubber off gas.
Conclusions
The measurements from the isokinetic sampling showed an average liquidingas
concentration of 0.19wt% with a separator liquid removal efficiency of 68%.
The vendor guarantee separator performance of 0.1 Usgal/MMsft3 (or 13
liters/MMsm3) carryover in the gas, which equates to a separation efficiency of
99.8%, is by far not being achieved.
Ref OG.04.50720
CASE 9 PROPRIETARY SEPARATOR - EVALUATION
10/2/2012 34
Copyright of Shell Global Solutions International B.V.
Bend in horizontal plane
violating 10D straight length
requirement.
V-1410
Propane
compressor
suction
scrubber
CASE 10 - INCORRECT INLET PIPING TO SUCTION
SCRUBBER
Case 10 Pre-start-up audit, July 2005

35 10/2/2012
Copyright of Shell Global Solutions International B.V.
HOW SHOULD WE GET IT RIGHT?
5
36 10/2/2012
Copyright of Shell Global Solutions International B.V.
HOW SHOULD WE GET IT RIGHT?
Understand the problem and how to avoid it.
Follow established good practice:
Use the Separator DEP
Eliminate slugs and keep them from re-forming
Pipework configuration correct
Dont delegate design responsibility:
Put high level philosophical requirements in BOD & BDP
Ensure that our requirements are fulfilled:
Project spec contractor to correctly express our philosophical
requirements in the EPC bid document
EPC contractor to purchase accordingly
EPC contractor to construct accordingly
37 10/2/2012
Copyright of Shell Global Solutions International B.V.
Principal
(asset owner)
Design
contractor
Vendor Fabricator
relationship
Who is making the decisions?
Who is truly providing the guarantee?
Where is the expertise?
Who really knows how the equipment will
perform?
Technical
advisor
r
e
l
a
t
i
o
n
s
h
i
p

Is the process engineering expertise in the project at the Principals end or the other end?
There is no reason for the expertise not to be at the Principals
end.
That expertise should be you!
relationship relationship
RELATIONSHIPS & EXPERTISE
10/2/2012 38
Copyright of Shell Global Solutions International B.V.
THANK YOU FOR YOUR ATTENTION

39 10/2/2012
Copyright of Shell Global Solutions International B.V.
DEP 31.22.05.11-Gen. September 2002
In E&P Offshore service
Separator handling natural-flowing production from:
a) its own platform 1.2
b) another platform or well jacket in shallow water 1.3
c) another platform or well in deep water 1.4
Separator handling gas lifted production from:
a) its own platform 1.4
b) another platform or well jacket 1.5
In E&P Onshore service
Separator handling natural flowing production, or gas plant inlet separator in:

a) flat or low rolling country 1.2
b) hilly country 1.3
Separator handling gas lifted production in:
a) flat or low rolling country 1.4
b) hilly country 1.5
In Refineries and Chemical plants:
The design margin ranges typically from

1.15 to 1.25

SURGE FACTORS -
For the production separator upstream of the compressor suction
scrubber
10/2/2012 40
Copyright of Shell Global Solutions International B.V.
CORROSION EROSION
10/2/2012 41
Copyright of Shell Global Solutions International B.V.
THRUST BEARING (BOTTOM) & SEAL
10/2/2012 42
Copyright of Shell Global Solutions International B.V.
RECIPROCATING COMPRESSOR OUTBOARD
DISCHARGE VALVE
10/2/2012 43