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1B1921-1-IES-1B-M-RPT-99-0007
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HYSYS SIMULATION REPORT
CONTENT
EXECUTIVE SUMMARY………………..……………………………………………………….......5
1 INTRODUCTION ................................................................................................ 6
2 DEFINITIONS .................................................................................................... 10
5 SIMULATION INPUT....................................................................................... 17
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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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2 DEFINITIONS
2.1 ABBREVIATIONS
Table 2.1: List of Abbreviations
ABBREVIATION MEANING
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ref Reference
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2.2 REFERENCES
The reference documents required to prepare this report are presented in Table 2.2
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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.
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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.
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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.
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5 SIMULATION INPUT
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6 SIMULATION RESULTS
The results of the simulation are presented in ref. 4
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