PROCESS DESIGN

BASIS

Doc. No. : DB-1718-107-P312-0201 Rev. No. : 9 Class : 1

PROCESS DESIGN BASIS

UNIT 107: NGL FRACTIONATION

9 04/08/2010 Approved for Construction OIEC MHM MA MMF AAP

8 09/02/09 Approved for Construction OIEC MHM MA MMF AAP

7 07/12/08 Approved for Design OIEC MHM MA MMF AAP

6 05/10/08 Approved for Design OIEC MHM MA MMF AAP

5 11/08/08 Approved for Design OIEC MHM MA MMF AAP

4 13/11/07 Approved for Design WP KK RI RPW MS

3 04/10/07 Approved for design WP KK RI RPW MS

2 24/05/07 Approved for Design WP SP JIS RPW MS

1 10/05/07 Issued for Design WP SP JIS RPW MS

0 20/04/07 Issued for Company Approval WP SP JIS RPW MS

A 11/04/07 Issued for Internal Review WP SP JIS RPW

REV. DATE DESCRIPTION ORIG. PRPD CHKD APP’D AUTH’D

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Doc. No. : DB-1718-107-P312-0201 Rev. No. : 9 Class : 1

CONTENTS
1. DOCUMENT SCOPE ................................................................................ 5
2. INTRODUCTION....................................................................................... 5
3. PROJECT OVERVIEW ............................................................................. 5
3.1 Plant Description................................................................................... 6
4. CODES AND STANDARDS...................................................................... 7
5. REFERENCE DOCUMENTS .................................................................... 7
6. ABBREVIATIONS ..................................................................................... 7
7. DEFINITIONS ........................................................................................... 8
8. DESIGN BASIS......................................................................................... 9
8.1 Feedstock Characteristics and Capacity ............................................... 9
8.2 Product Specifications ........................................................................ 10
8.3 Battery Limits Conditions .................................................................... 12
8.4 Turndown Ratio................................................................................... 12
9. GENERAL DESIGN CONSIDERATIONS ............................................... 13
9.1 Number of Trains ................................................................................ 13
9.2 Equipment Design Requirements ....................................................... 13
9.3 Metallurgy ........................................................................................... 13
9.4 Sparing Philosophy ............................................................................. 14
10. PROCESS DESCRIPTION ..................................................................... 14
10.1 107-C-101: Depropanizer ................................................................... 14
10.2 107-C-102: Debutanizer...................................................................... 15
10.3 Specific Loop Description.................................................................... 15
11. SAFETY AND SHUTDOWN INTERLOCK .............................................. 16

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11.1 System Protection............................................................................... 16

11.2 Process Upsets................................................................................... 17
11.3 Depressurisation ................................................................................. 17

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 PROCESS DESIGN
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Doc. No. : DB-1718-107-P312-0201 Rev. No. : 9 Class : 1

1. DOCUMENT SCOPE

This document defines the main principles to be considered for the design and the implementation of the
onshore facilities of Unit 107: NGL Fractionation where liquid propane cut, liquid butane cut and C5+ cut
are produced in this Unit.

Dry Sour Liquid propane and butane cuts is treated in downstream Units 114 & 115 to remove Sulphur
compounds and Mercaptans and redried in order to comply with commercial grade propane and butane
specifications.

C5+ cut is sent to Unit 103 and mixed with the stabilized condensate.

2. INTRODUCTION

The IDRO/OIEC/IOEC Consortium has been contracted by the National Iranian Oil Company (NIOC) to
conduct the EPCC for SOUTH PARS Phases 17 & 18 Project. This Project includes Offshore Facilities,
wells, platform and undersea pipelines, and Onshore Facilities for the processing of the reservoir fluid.

WorleyParsons Pty Ltd has in turn been contracted by the IDRO/OIEC Consortium to conduct the Basic
Engineering and FEED for SOUTH PARS Phases 17 & 18 for the Onshore facilities.

The South Pars Phases 17 & 18 Project offshore work-scope is being carried out by a separate Offshore
Consultant. WorleyParsons will lead, identify and coordinate deliverables required to manage the physical
interfaces between the Onshore and Offshore Design Consultants.

3. PROJECT OVERVIEW

The Iranian South Pars field is the largest discovered offshore gas field in the world, located 100 km
offshore in the Persian Gulf. Reservoir fluids are transported to shore to the mainland (ASSALUYEH) at a
distance of 105 km. approximately, for further treatment.

South Pars Phases 17 & 18 are a further development of the South Pars gas field consisting essentially of
two 1000 mmscfd gas treatment trains.

The facilities shall be developed on the basis of supplying treated lean gas to the domestic gas network
and ethane gas to the nearby petrochemical complex at the required specifications while maximising liquid
recovery as propane and butane and stabilised hydrocarbon condensate for export.

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A new interconnecting pipeline shall transport the lean gas produced to the domestic gas distribution
network via fiscal metering facilities.

The produced condensate shall be stored in dedicated storage facilities, periodically pumped through a
condensate export pipeline to a SBM via fiscal metering facilities.

The treated propane and butane shall be stored separately in refrigerated atmospheric double wall
storage tanks, periodically pumped through a dedicated loading pipelines network to LPG carriers berthed
at a jetty via fiscal metering facilities.

3.1 Plant Description

The main functions of the Onshore processing facilities are:

• Reception facilities for the HP fluids and separation of the raw gas and condensate/water/MEG
mixture.

• Condensate stabilisation producing stabilised condensate for storage and export. The light ends
are recycled to the HP gas system. One condensate flashing Unit, normally not operated, is
provided as a back-up to the stabilisation facilities.

• Gas treatment facilities producing sales gas, gaseous ethane and NGL’s consisting of:

− H2S/CO2 removal from gas.

− Dehydration Unit, using molecular sieves technology.

− Mercury guard.

− Ethane extraction Unit, producing sales gas, gaseous ethane and NGL.

− Gas export compression.

• Ethane treatment for CO2 and COS removal for further export.

• NGL fractionation facilities to produce sour liquid propane, butane and condensate. This
condensate is routed to the condensate stabilisation system for treatment.

• Propane and butane treatment for Mercaptans removal and drying for storage and export.

• Propane and butane separate atmospheric storage tanks, double wall, and full containment,
refrigerated with reinforced concrete external walls.

• MEG regeneration and injection Unit.

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• Sulphur recovery producing liquid sulphur for solidification, granulation and export.

• Utilities, Offsites as required for operation.

4. CODES AND STANDARDS

Instrumentation and Systems will be designed and fabricated in accordance with engineering codes and
standards listed in document:

DB-1718-999 P332-0203: List of Applicable Codes & Industry Standards

5. REFERENCE DOCUMENTS

This document is complemented by the following documents:

• DB-1718-999-P312-0202: Process Design Basis and Overall Process Description.

• DB-1718-999-P332-0204: Basic Engineering Design Data for Onshore Facilities.

• DB-1718-999-P312-0205: Process Sizing Criteria.

• DB-1718-999-P312-0209: Preliminary Process Description for Safety Systems.

• DB-1718-999-P312-0216: Control, Operating and Maintenance Philosophy.

• DB-1718-999-P312-0213: Utilities Philosophy.

• DB-1718-999-P312-0203: Design Basis for PID Development.

• DB-1718-999-P332-0201: Equipment and Engineering Documents: Identification and Numbering

for Onshore Facilities.

• RT-1718-999-P312-0007: Emergency Depressurisation And Minimum Temperature Report

6. ABBREVIATIONS

AFC Approved for Construction

AFD Approved for Design

ASTM American Society for Testing & Measurement

BL Battery Limit

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Doc. No. : DB-1718-107-P312-0201 Rev. No. : 9 Class : 1

BEDD Basic Engineering Design Data for Onshore Facilities

COS Carbonyl Sulphide

EPCC Engineering, Procurement, Construction and Commissioning

FEED Front End Engineering Design

IDRO Industrial Development and Renovation Organisation

IFP Institute Francais du Petrol

IOEC Iranian Offshore Engineering and Construction Company

MEG Mono Ethylene Glycol

mmscfd Million standard cubic feet per day

NGL Natural Gas Liquids

NIOC National Iranian Oil Company

OIEC Oil Industries Engineering and Construction

PFD Process Flow Diagram

P&ID Piping & Instrumentation Diagram

PEP Project Execution Plan

POGC Pars Oil and Gas Company

SBM Single Buoy Mooring

UFD Utility Flow Diagram

WP WorleyParsons Services Pty Ltd

7. DEFINITIONS

Within this specification the following definitions shall apply:

COMPANY: Shall mean PARS OIL & GAS COMPANY (POGC), or his representative.

CONTRACTOR: Shall mean the Consortium of IDRO, OIEC and IOEC in charge of EPCC realisation of
SOUTH PARS Phases 17 & 18 in the CONTRACT with COMPANY, or his representative.

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in any way made public without permission of the owner.

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CONSTRUCTION CONTRACTOR: Shall mean the party sub-contracted by the CONTRACTOR for
construction WORK, or his representative.

WORK: Shall mean all and any of the works and / or services and/or materials required to be provided by
the CONTRACTOR or CONSTRUCTION CONTRACTOR.

VENDOR: Shall mean any person, firm or business which manufacture or supply materials, equipment or
services for the performance of any item of WORK.

8. DESIGN BASIS

8.1 Feedstock Characteristics and Capacity

Two cases have to be considered for the design of the Unit 107: summer and winter cases.

The following table gives the compositions and conditions of the Unit 107 feedstock at 107-C-101 inlet for
one train.

DESIGN CASE SUMMER DESIGN CASE WINTER

Pressure (1) 21.8 barg 21.8 barg

Temperature (1) 93.3 °C 89.4 °C

DESIGN FLOWRATE

• kmol/h 1692 1570

Composition

Ethane % mole 0.16 0.17

Propane % mole 55.51 59.11

iC4 % mole 10.51 10.52

nC4 % mole 16.22 15.89

iC5 % mole 4.92 4.39

nC5 % mole 4.44 3.86

C6 cut % mole 3.87 2.98

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C7 cut % mole 2.21 1.53

C8 cut % mole 1.14 0.74

C9 cut % mole 0.31 0.20

C10 cut % mole 0.075 0.048

C11 + % mole 0.015 0.011

H2S ppm mole Traces Traces

COS % mole 0.007 0.010

M-Mercaptan % mole 0.065 0.064

E-Mercaptan % mole 0.405 0.363

Pr1Thiol % mole 0.12 0.093

Bu1Thiol % mole 0.017 0.012

HX1Thiol % mole 0.005 0.003

Molecular weight 54.31 52.86

Note: (1) Pressure and temperature are given at the inlet of the 107-C-101

8.2 Product Specifications

Products of Unit 107 are:

• Propane to propane treatment (Unit 114)

• Butane to butane treatment (Unit 115)

• C5+ to Condensate Stabilization (Unit 103)

The liquid propane produced in the NGL fractionation complies with the following specification:

Description Unit Specification Test Method ASTM

Ethane %mol 0.4 max. GC

Propane %mol 98.0 min. GC

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Butanes %mol 1.4 max. GC

Pentane + %mol 0.01 max GC

Vap. pressure @ 100°F psig 200 max. D2598

Residue on evaporation ppm 0.05 max D2158

Sulphur and moisture content specification is achieved in Unit 114: Propane Treatment and Drying.

The liquid butane produced in the NGL fractionation complies with the following specifications:

Description Unit Specification Test Method ASTM

Ethane %mol 0.08 max. GC

Propane %mol 2.0 max. GC

Butane %mol 97.5 min. GC

Pentane %mol 0.32 max GC

Vap. pressure @ 100°F psig 70 max. D2598

Volatile residue on evaporation ppm 0.05 max D2158

Sulphur and moisture content specification is achieved in Unit 115: Butane Treatment and Drying.

The C5+ is sent to Condensate Stabilization (Unit 103) where it is mixed with stabilized condensate.
Specification for the total stabilized condensates is as follows:
• RVP @ 37.8°C: Max. 12 psia (winter)
Max. 10 psia (summer)
• Salt content: 10 mg/lt max
• Free water : 500 ppm max
• Mercaptans: less than 400 ppm wt

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Doc. No. : DB-1718-107-P312-0201 Rev. No. : 9 Class : 1

8.3 Battery Limits Conditions

The operating conditions of the main streams to and from the Unit 107 is as follows:

Pressure (barg) Temperature (°C) Comments

Operating Design Operating Design

HC from Unit 105 from 21.8 39 93 155 At Unit 107 B.L.

Train 1 & Train 2
21.8 28 93 155 At 107-C-101 inlet.

C3 Recycle from Unit 40 65.7 40 -42/85 At Unit 114 B.L.

114
Feeds
C4 Recycle from Unit 40 66.4 40 -6/85 At Unit 115 B.L.
115

Sour washing butane

12.8 46.7 (2) 40 85 At Unit 114 B.L.
cut from Unit 113

Propane to Unit 114 37.2 50 62.5 -45/85 At Unit 107 B.L.

Products Butane to Unit 115 14.5 24 40 -45/85 At Unit 107 B.L.

C5+ to Unit 103 10.5 19.6 60 155 (1) At Unit 107 B.L.

(1) Design temperature of 107-A-103 Outlet (Fan Failure Case).

(2) Design pressure of 113-D-102, C4 Washing Drum

(3) Deleted

8.4 Turndown Ratio

Each train is designed to handle 40% of the feed gas flowrate given in Section 8.1.

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9. GENERAL DESIGN CONSIDERATIONS

9.1 Number of Trains

The NGL fractionation is implemented as 2 X 50% trains, one train per phase.

9.2 Equipment Design Requirements

9.2.1 Columns

107-C-101: Depropanizer

The operating pressure of the Depropanizer is set at 22.3 bara at Top & 22.6 bara at Bottom to ensure a
condensation of the propane cut in an air cooler.

There are 16 actual trays in the top section, 27 actual trays for the bottom section (four passes trays) (also
includes the bottom draw tray). Tray details and design shall be confirmed during detailed engineering.

107-C-102: Debutanizer

The operating pressure of the debutanizer is set at 8.2 bara at Top & 8.5 bara at Bottom to ensure a
condensation of the butane cut in an air cooler.

There are 18 actual trays in the top section, 22 actual trays for the bottom section (also includes the
bottom draw tray). Tray details and design shall be confirmed during detailed engineering.

9.2.2 Exchangers

107-E-104: Butane cooler

Butane is cooled against sea water to achieve a temperature of 40°C at the inlet of Unit 115 (a
temperature of 35°C to 40°C is recommended in the Butane Treatment Unit).

9.3 Metallurgy
Materials of construction for equipment and piping shall be based on the Material Selection and
Corrosion Control Report (RP-1718- 171-6300-0002) and the Material Flow Diagram for Unit 107 (MFD-
1718-107-0021-0001).

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All materials selected for sour service shall comply with NACE MR 01-75/ISO 15156 as a minimum and
with Specifications: Metallurgical Requirements for Carbon Steel in Sour Wet Service (Piping & Equipment
Subject to SSCC & HIC) (RP-1718-999-6300-0002) and Metallurgical Requirements for Carbon Steel in
Sour Service (Piping & Equipment Subject to SSCC only) (RP-1718-999-6300-0003) as appropriate.

Lethal service classification shall apply to any pressure vessel or rotating equipment handling poisonous
fluids. The data sheets must identify that such equipment is in lethal service.

The metallurgy selection shall consider corrosive fluids and a plant service life of 25 years.

9.4 Sparing Philosophy

Also refer to DB-1718-999-P312-0205: Process Sizing Criteria

All pumps are spared except 107-P-104 (HC Sump Drum Pump)

10. PROCESS DESCRIPTION

The fractionation Unit 107 comprises of two distillation columns (107-C-101: Depropanizer and
107-C-102: Debutanizer along with their respective reboilers and condensers).

10.1 107-C-101: Depropanizer

Deethanizer bottoms (Unit 105) from train 1 and 2 are sent to 107-C-101 under level control resetting flow
control.

The Depropanizer operates at 22.3 bara at Top & 22.6 bara at Bottom and is equipped with both
condenser and reboiler.

The overhead propane gas of 107-C-101 is air-cooled in the Depropanizer Condenser 107-A-101 and
condensed at 60 °C. The liquid propane product is routed to the Depropanizer Reflux Drum 107-D-101.
Part of the liquid is returned as reflux to the top tray of the Depropanizer under flow control by the
Depropanizer Reflux Pump 107-P-101 A/B. The remaining is sent under 107-D-101 level control resetting
flow control by the Propane Feed Pump 107-P-107 A/B to the Propane treatment unit (Unit 114) where
COS and Mercaptans are removed.

The Depropanizer Reboiler 107-E-101 uses low pressure saturated steam as heating medium. The
Depropanizer bottom temperature is maintained about 138°C.

The bottom product containing butanes and heavier is sent to the Debutanizer.

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10.2 107-C-102: Debutanizer

Depropanizer bottoms is sent to 107-C-102 under level control resetting flow control and mixed with the
sour washing C4 cut from Unit 114.

The Debutanizer operates at 8.2 bara at Top & 8.5 bara at Bottom and is equipped with both condenser
and reboiler.

The overhead butane gas of the column is air-cooled in the Debutanizer Condenser 107-A-102 and
condensed at 60°C. The liquid butane product is then routed to the Debutanizer Reflux Drum 107-D-102.
Part of the liquid is pumped from the Debutanizer Reflux Drum by the Debutanizer Reflux Pumps
107-P-102 A/B and returned under flow control to the top tray of the Debutanizer as reflux. The remaining
is pumped by Butane feed pumps 107-P-103 A/B, cooled by sea water down to 40°C in the Butane Cooler
107-E-104 and sent to Butane treatment unit (Unit 115), under 107-D-102 level control resetting flow
control.

The Debutanizer Reboiler 107-E-102 uses low pressure saturated steam as heating medium. The
Debutanizer bottom temperature is maintained about 131°C.

The Debutanizer bottom liquid is pumped by Condensate circulation pumps 107-P-105 A/B and air-cooled
to 60°C to avoid flashing. The liquid is sent under 107-C-102 level control resetting flow control to the
Condensate Stabilization Unit (Unit 103) to be mixed with stabilized condensates.

10.3 Specific Loop Description

10.3.1 Depropanizer and Debutanizer Overhead Section Pressure:

The column pressure is controlled by a control valve located on the overhead line upstream of the
aircooler.

The pressure of the Reflux Drum, i.e. the temperature of condensation, is controlled by:

• Opening of the pressure drop control valve, on aircooler hot by-pass, if pressure decreases,

• Opening of the pressure control valve connected to flare, if pressure increases.

These two controllers have different set points (dead band provided) so that the two control valves can not
be opened simultaneously.

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10.3.2 Low Pressure Steam Flowrate to Reboilers:

The low pressure steam flowrate to the two Reboilers (107-E-101 and 107-E-102) is controlled by the
steam flowrate controller, which is reset by the temperature of the sensitive tray of the corresponding
column.

11. SAFETY AND SHUTDOWN INTERLOCK

11.1 System Protection

11.1.1 Depropanizer Column with Reboiler, Condenser and Reflux

Drum

The top of the column and the reflux drum i.e. the overheads system is designed for 28.0 barg. The
bottom of the column and Reboiler is designed for 28.3 barg (to include a pressure drop of 0.3 bar across
the trays). The column is protected by a relief valve located at the top of the column and set at 28.0 barg.
The reflux drum is protected by a relief valve set at 28.0 barg.

11.1.2 Propane Export

The Propane Feed Pump 107-P-107 A/B discharge and downstream Units is designed for 50 barg.

11.1.3 Debutanizer Column with Reboiler, Condenser and Reflux

Drum

The column overheads system i.e. top of the column and the reflux drum is designed for 11.0 barg. The
bottom of the column and Reboiler is designed for 11.3 barg (to include a pressure drop of 0.3 bar across
the trays). The column is protected by a relief valve located at the top of the column and set at 11.0 barg.
The reflux drum is protected by a relief valve set at 11.0 barg.

11.1.4 Butane Export

The Butane feed pumps 107-P-103 A/B, 107-E-104 shellside and downstream Units is designed for
24 barg.

11.1.5 Condensate Export

The Condensate circulation pumps 107-P-105 A/B and 107-A-103 are designed for 19.6 barg.

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11.1.6 Steam Condensate

The steam condensate drum 107-D-104 and associated condenser is designed for 2.0 barg and 175oC.
Relief valves on the steam condensate drum are installed to protect the vessel against overpressure due
to tube rupture in the Reboilers or due to feed control valve failure. The condensate pipework, from
Reboiler 107-E-101 tubeside to the inlet of the condensate surge drum is rated as 300#. This is separated
from the 150# condensate return from Reboiler 107-E-102.

11.2 Process Upsets

Three levels of shutdown are provided to ensure safety and operability of the plant.

Also Refer to DB-1718-999-P312-0209: Preliminary process description for Safety Systems for
supplementary information.

The level 2 which corresponds to the Unit shutdown is activated by HS to shutdown Unit 107.

This Level 2 HS will close only the SDVs located on the feed line from Unit 105 train 1 and train 2 and
product lines i.e., propane to Unit 114, butane to Unit 115 and condensate to Unit 103.

Level 2 is activated by simultaneous process upsets in both trains of Units 104 and 105.

11.3 Depressurisation
For blowdown philosophy refer to DB-1718-999-P312-0209: Preliminary process description for Safety
Systems

• Level 1 depressurisation:

Level 1 depressurisation is generated by operator through two push buttons. ESD1 gives the authorization
for EDP1: depressurisation of the train.

Unit 107 is depressurised through four subsystems:

• 107-C-101, 107-E-101, 107-P-101 and 107-P-107,

• 107-D-101 and 107-A-101,

• 107-C-102, 107-P-102 and 107-E-102,

• 107-D-102 and 107-A-102.

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