HYSYS SIMULATIOIN REPORT

1B1921-1-IES-1B-M-RPT-99-0007

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 HYSYS SIMULATION REPORT

CONTENT

EXECUTIVE SUMMARY………………..……………………………………………………….......5

1 INTRODUCTION ................................................................................................ 6

1.1 BACKGROUND ............................................................................................. 6

1.2 PROJECT SCOPE ........................................................................................... 7
1.3 DOCUMENT OBJECTIVE ............................................................................ 7

2 DEFINITIONS .................................................................................................... 10

2.1 ABBREVIATIONS ....................................................................................... 10

2.2 REFERENCES .............................................................................................. 12

3 SYSTEM OF UNIT ............................................................................................ 13

4 SIMULATION OVERVIEW ............................................................................ 14

4.1 SIMULATION MODEL ............................................................................... 14

4.1.1 SUCTION SCRUBBERS ........................................................................................... 14
4.1.2 BOOSTER COMPRESSORS .................................................................................... 14
4.1.3 DISCHARGE COOLERS .......................................................................................... 14
4.1.4 PRESSURE CONTROL VALVE ............................................................................... 14
4.2 SIMULATION FLOWSHEET ..................................................................... 15

5 SIMULATION INPUT....................................................................................... 17

5.1 FLUID PACKAGE ....................................................................................... 17

5.2 GAS COMPOSITION ................................................................................... 17
5.3 PROCESS DATA.......................................................................................... 18
5.4 PRESSURE DROP........................................................................................ 18

6 SIMULATION RESULTS ................................................................................. 19

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LIST OF TABLES
TABLE 2.1: LIST OF ABBREVIATIONS............................................................................................ 10
TABLE 2.2: REFERENCE DOCUMENTS........................................................................................... 12
TABLE 3.1: SYSTEM OF UNITS......................................................................................................... 13
TABLE 5.1: GAS COMPOSITION ....................................................................................................... 17
TABLE 5.2: PROCESS PARAMETERS............................................................................................... 18
TABLE 5.3: PRESSURE DROP ALLOWANCE.. ................................................................................ 18

LIST OF FIGURES
FIGURE 1.1: SCHEMATICS FOR LBCS UPGRADE .......................................................................... 8
FIGURE 1.2: MODIFIED PROCESS FLOW DIAGRAM; LBCS .......................................................... 9
FIGURE 4.1: HYSYS SIMULATION FLOW SHEET OF BOOSTER COMPRESSION TRAIN ...... 16

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EXECUTIVE SUMMARY
The objective of this document is to carry out process simulation of the booster
compression train required for the LBCS low suction compression project. The
compression system which is a 2 x 100% system has each train with a suction
scrubber (MBG-3740/3750), a booster compressor (CAE-1020/1120), and a discharge
cooler (HAL-2020/2120). There is a pressure control valve downstream of the coolers
on the line that feeds the existing trains.
The simulation was carried out using HYSYS V9. The gas composition used was
based on the existing gas composition available. The scrubber receives gas from the
inlet header at 25 oC, 15 barg and 93.00 MMSCFD. The scrubbed gas is compressed
to 45 barg by the compressor CAE-1020/1120 and the discharge coolers HAL-
2020/2120 cool the gas such that the inlet to the existing compressor trains is 25 °C.
The gas from the cooler directly feeds the departing pipeline when low pipeline
pressure is required. When the booster compressor cannot meet the required pressure
of the departing pipeline, the gas from the discharge cooler is fed to the existing
compressor trains for further boosting. For this scenario, the pressure of the gas from
the coolers is reduced to the required suction pressure of 28 barg of the existing trains
using a control valve. A pressure drop of 1 barg is accounted for across the cooler and
suction scrubber.

From the results, the gas would be compressed to a temperature of 128.9 °C (which is
within acceptable limit) and would need to be cooled to 33.1 °C in the case the gas is
to be fed to the existing compressor trains. The pressure drops of 16 barg across the
control valve would mean the gas would tie back into the existing train at 25 °C and
28 barg. The heat flow and power required by the compressor to compress the gas are
1.860 × 107 kJ/hr and 5167 hp respectively while the cooler duty is 1.994 × 107 kJ/hr.
However, if the gas is to be fed directly to the pipeline, it would be cooled to 40 °C
and the required cooler duty would be 1.852 × 107 kJ/h.
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1 INTRODUCTION
1.1 BACKGROUND
West African Gas Pipeline Company (WAPCo) has engaged International Energy
Services Limited (IESL) to carry out Conceptual studies and the Front-End
Engineering Design (FEED) that will proffer solutions to low suction pressure effect
on their compression systems at Lagos Badagry Compression Station (LBCS). The
existing LBCS; a facility that receives gas from Itoki RMS via Alagbado tee consists
of two trains of two stage compression systems that compresses the gas for export to
Ghana. The inlet of the facility has a pig launcher, which is bypassed during non-
pigging operations to the inlet scrubber (MBG-3800). The gas from the inlet scrubber
feeds the first stage suction scrubber of whichever train is online MBG-3720 or
MBG-3730. The scrubbed gas is compressed in the first stage compressor (CAE-1000
or CAE-1100) and then cooled in the first stage discharge cooler HAL-2000 or HAL-
2100). The cooled gas then feeds the second stage suction scrubber and the whole
process is repeated for the second stage compression. There is an anti-surge recycle
line from downstream of each cooler to upstream of each suction scrubber to prevent
surges. The gas from the second stage discharge cooler is then metered and feed to the
departing pipeline to Ghana. There are utility systems that support the main process;
relief system, depressuring system, closed drain system.
The minimum design suction pressure of the compressors is 28 barg and suction
pressure as low as 27 barg has been recorded with expectation of as low as 15 barg
suction pressure. As the compressor would not be able to operate below the minimum
design suction pressure, a conceptual study has been carried out to find a solution to
the problem. Five various options were proffered as solution and review and analysis
of the options, the best option arrived at was to incorporate a booster compressor
system that would boost the expected low pressure of 15 barg to the required existing
compressor trains and have the option to directly feed the boosted gas to the departing

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pipeline, in instances low departing pipeline pressure is required. A schematic

representation of this process is presented in Figure 1.1.
The Booster compressor systems would be a 2 x 100% train with either train able to
supply either of the existing compressor trains. Each compressor system would have a
suction scrubber (MBG-3740/3750), a compressor (CAE-1020/1120) and discharge
cooler (HAL-2020/2120). The compressors which have a compression ratio of 3
would boost the expected minimum pressure of 15 barg to 45 barg. The booster gas
after being cooled would be fed either directly to the pipeline or to the existing
compressor trains. It would be fed to the pipeline if the required pipeline discharge
pressure is within 45 barg otherwise it would be fed to the existing compressor trains.
In the latter case, the pressure of the gas would need to be reduced to the 28 barg
currently operating suction pressure of the existing compressors using a pressure
control valve. This process is captured in the modified Process Flow Diagram of the
facility as seen Figure 1.2.

1.2 PROJECT SCOPE

The scope of the project involves producing all the deliverables required for the
Front-End Engineering Design for the LBCS Booster Compression Project as
described in the Background in Section 1.1

1.3 DOCUMENT OBJECTIVE

The objective of this document is to carry out process simulation of a single stage
booster compression train of LBCS low suction compression project. The
compression train consists of: suction scrubber, booster compressor, cooler and
pressure control valve.

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Figure 1.1: Schematics for the LBCS upgrade

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Figure 1.2: Modified Process Flow Diagram; LBCS

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2 DEFINITIONS
2.1 ABBREVIATIONS
Table 2.1: List of Abbreviations
ABBREVIATION MEANING

Barg Bar guage

CAE 1000 Existing Train No.1 First Stage Compressor

CAE 1100 Existing Train No. 2 First Stage Compressor

CAE 1020 Train No. 1 Booster Compressor

CAE 1120 Train No. 2 Booster Compressor

FEED Front End Engineering Desing

HAL 2000 Existing Train No. 1 First Stage Cooler

HAL 2100 Existing Train No. 2 First Stage Cooler

HAL 2020 Train No. 1 Booster Compressor Cooler

HAL 2120 Train No. 2 Booster Compressor Cooler

HMB Heat and Material Balance

IDC Inter Disciplinary Check

IESL International Energy Services Limited

LBCS Lagos Beach Compression Station

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Table 2.1: List of Abbreviations (Contd)

ABBREVIATION MEANING

MBG 3800 Existing Inlet Scrubber

MBG 3720 Existing Train No. 1 First Stage Scrubber

MBG 3730 Existing Train No.2 First Stage Scrubber

MBG 3740 Train No. 1 Booster Compressor Scrubber

MBG 3750 Train No. 2 Booster Compressor Scrubber

MMSCFD Million Standard Cubic Feet per Day

PCV 2121 Pressure Control Valve

PCV 2122 Pressure Control Valve

PFD Process Flow Diagram

PID Piping and Instrumentation Drawing

ref Reference

RPM Revolution Per Minute

WAGP West African Gas Pipeline

WAPCo West African Gas Pipeline Company

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2.2 REFERENCES
The reference documents required to prepare this report are presented in Table 2.2

Table 2.2: Reference Documents

S/N DOCUMENT NO. DESCRIPTION

1 WAGP-1-WIL-1B-M-PFD-99-0001 PFD – Compressor Trains No. 1 and 2

Lagos Beach Compressor Station

2 1B1921-1-IES-1G-M-RPT-99-0001 Conceptual Study Report

3 1B1921-1-IES-1G-M-BOD-99-0001 Basis of Design

4 1B1921-1-IES-1B-M-HMB-99- Heat and Material Balance

0002

5 WAGP-1-WIL-1B-M-PID-99-0002 Train No. 1 Compressor Suction

Scrubber, Lagos Beach Compressor
Station

6 WAGP-1-WIL-1B-M-PID-99-0003 Train No. 1 Compression, Lagos

Beach Compressor Station

7 WAGP-1-WIL-1B-M-PID-99-0007 Train No. 2 Compressor Discharge

Coolers, Lagos Beach Compressor
Station

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3 SYSTEM OF UNIT

The primary units to present results for this simulation shall be International System
(S.I) of units. However, in some cases, imperial units may be used. Some other units
which have international industry recognition and are neither part of the S.I units nor
Imperial units may be used. The table below shows the units that would be used for
the major parameters of the simulation.

Table 3.1: System of Units

QUANTITY UNIT
Pressure barg
Temperature °C
Std. Volumetric flow rate (gas) MMSCFD
Volumetric flow rate (liquid) bbls/day
Mass flow rate kg/h
Mass Density kg/m³
Enthalpy kJ/kg
Duty kW
Heat flow kJ/h
Viscosity cP

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4 SIMULATION OVERVIEW
4.1 SIMULATION MODEL
4.1.1 SUCTION SCRUBBERS (MBG-3740/3750)
The scrubber removes traces of liquid droplets from gas stream to protect compressor
from damage and failure, minimize power consumption while achieving high pressure
ratio. From the existing gas composition, there is no liquid entrained in the gas. The
suction scrubber was represented with two phase separator unit operation.

4.1.2 BOOSTER COMPRESSORS (CAE-1020/1120)

The booster compressor with a compression ratio of 3 increases the suction pressure
of 15 barg to 45 barg. The heat flow required for the compression is 1.860 × 107 kJ/h
and this is based on adiabatic and polytropic efficiency of 75 % and 78 %
respectively. The booster compressor was represented with the centrifugal compressor
unit operation.

1.1.3 DISCHARGE COOLERS (HAL-2020/2120)

The cooler cools the compressed gas at 128.9 °C to the required temperature. The
required discharge temperature is based on the destination of the gas. If the gas is to
be fed to the existing compressor, the gas is cooled to 33.1 °C such that the gas meets
the required 25 °C at the existing trains after pressure reduction. If the gas is to be fed
to the pipeline, it would be cooled to the pipeline required 40 °C. In the former case
the cooler duty would be 1.994 × 107 kJ/h while for the latter, the cooler duty would
be 1.994 × 107 kJ/h. The discharge cooler was represented with the cooler unit
operation.

4.1.4 PRESSURE CONTROL VALVE (PCV-2121/2122)

The control valve, which operates when the gas is to be fed to existing compressor
trains, receives the cooled gas at 44 barg & 33.1 °C and reduces the pressure to the

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required suction pressure of 28 barg for the existing trains. The corresponding
temperature associated with the pressure reduction is 25 °C which is the required
temperature for the existing compressor train. The pressure control valve was
represented with the control valve unit operation.

4.2 SIMULATION FLOWSHEET

The HYSYS simulation flow sheet for the booster compression train is presented in
Figure 4.1. The 93.00 MMSCD of gas at 15 barg and 25 °C coming from inlet gas
header feeds the booster compressor suction scrubber of the train online (MBG
3740/3750). The gas exiting the scrubber leaves at a temperature of 24.45 oC and a
pressure of 14 barg as 1 barg pressure drop is accounted for across the scrubber. There
is no liquid flow from the scrubber. As a compression ratio of 3 is used, the scrubbed
gas is compressed in the booster compressor (CAE-1020/1120), to a pressure of 45
barg with a corresponding discharge temperature of 128.9 °C. The temperature to
which the compressed gas is cooled depends on its destination. If the gas is to be fed
to the existing compressor trains, the gas is cooled to a temperature of 33.1 oC in the
discharge cooler (HAL-2020/2120). The pressure of this cooled gas is then reduced to
the required 28 barg at the suction of the existing compressor using a pressure control
valve. The temperature downstream of the pressure control valve would be the
required 25 °C. If the gas is to be fed directly to the pipeline, the gas would be cooled
to the 40 °C required in the pipeline. In the case of the discharge into the pipeline,
there is a 16 MMSCFD tap of to the fuel gas scrubber as fuel consumption for the
facility.

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Figure 4.1: HYSYS Simulation Flow Sheet of Booster Compression Train

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5 SIMULATION INPUT

5.1 FLUID PACKAGE

The fluid package selected for the simulation model is Peng Robinson.

5.2 GAS COMPOSITION

The composition of the gas as obtained from the existing system is presented in Table
5.1.
Table 5.1: Gas Composition
COMPOSITION MOL %
C1 88.74
C2 5.93
C3 1.28
iC4 0.26
nC4 0.26
iC5 0.09
nC5 0.06
C6+ 0.06
C7+ 0.10
N2 0.66
CO2 2.55
H2O 0.01

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5.3 PROCESS DATA

The simulation process parameters are presented in Table 5.2

Table 5.2: Process Parameters

PARAMETER VALUE REMARK

Std. Gas Flow rate (MMSCFD) 93 Ref. 1

Pressure of gas from inlet gas header (barg) 15 Ref. 1

Temperature of gas from inlet gas header (°C) 25 Ref. 1

Temperature required at existing trains (°C) 25 Ref. 1

Booster compressor suction pressure (barg) 14 Ref. 2

Temperature required at pipeline (°C) 40 Ref. 1

5.4 PRESSURE DROP

The pressure drop accounted for across process equipment is presented in Table 5.3

Table 5.3: Pressure Drop Allowance

EQUIPMENT PRESSURE DROP

ALLOWANCE
(BARG)
Suction Scrubber (MBG 3740/3750) 1

Cooler (HAL 2020/2120) 1

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6 SIMULATION RESULTS
The results of the simulation are presented in ref. 4

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