PROJECT: PROJECT NO: CLIENT: DOCUMENT NUMBER:

Universal/SIPEC SCPF-PETW
PETW- NTS-P-01002
Stubb Creek EPF Project JU11867 JOT

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Title Petrofac 12/12
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CONTENTS

CONTENTS................................
................................................................................................
................................... 2

1 NTRODUCTION................................
................................................................
....................................................... 3
1.1 Central Production Facility Design Capabilities ................................
.............................................. 3

2 PROCESS DATA ................................................................

...................................................................................... 4
2.1 Crude Oil Feed / Product Heat Exchnager ................................
..................................................... 4
2.2 Limitation of TVP Specification to Floating Roof Tanks: ................................
.................................... 5
2.3 Meteorological Data on Ambient Air Temperature................................
Temperature ........................................... 6
2.4 Expected Crude Oil Temperature During the Maximum Ambient Conditions ........... 7

3 CONCLUSION................................
.........................................................................................
......................... 9

4 REFEENCES................................
..........................................................................................
..........................10
 PROJECT: PROJECT NO: CLIENT: DOCUMENT NUMBER:
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1 INTRODUCTION

This technical note is intended to highlight the following aspects,

1. The design Crude oil Product specification and its actual TVP at various rundown
crude oil storage temperature

2. Establish and quantify the period of time during which the ambient temperature is
actually equal to design temperature or at possible peak ambientt temperature
temperature.

3. Process parameters that can be adjusted within the available design margin to
meet the required TVP specification for floating roof tanks during the peak
ambient temperature or design ambient temperature whichever is greater
greater.

1.1 Central Production Facility Design Capabilities

Presently the Stubb Creek CPF is designed to stabilise crude oil to meet the process
guarantee on TVP of 10.5 psia @ 37.8°C. The stabilised crude oil at 170°C at the stabiliser
bottom is cooled in two set of feed product
product exchangers before being further cooled to
rundown temperature in crude oil air cooler. The cooled stabilised crude oil is then
diverted to floating roof crude oil storage tanks. The floating roof tanks are considered in
present process configuration to avoid the requirement of blanketing gas and minimise the
vapour loss from the oil storage. It should be noted that 10% design margin are considered
with all process equipments over to the normal flowrates, while rundown cooler is
considered with 20% margin.

Figure 1.1- Process flow Schematic for Crude Oil Cooling

TO STABILISER
COLD FEED

STRM
13

STRM STRM
E-30501
HEAT EXCHANGER 13-C STRM 13-A
HC LIQUID FROM 1ST STAGE
13-B
SEPARATOR V-30302
STRM E-30502
HEAT EXCHANGER
133 DESALTER PACKAGE STRM STRM
STRM 9-A 9
132 TC

TO STABILISER
TC HOT FEED

STRM
STRM
11-A
14-A

STRM STRM
14-B 11

FROM STABILISER BOTTOM

E-30504
30504 STRM
STRM CRUDE OIL COOLER
15
14

CRUDE OIL
STORAGE TANK
TK-15101A/B
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2 PROCESS DATA
2.1 Heat Balance around Crude Oil Feed / Product Heat Exchangers

The process parameters envisaged at the exchangers inlet and outlet during the various
periods of operation are tabulated below. Refer to Figure1.1 for stream number

Table 2.1 - Process Parameters during normal operation.

E-30501
CASE A B C D
HX CONDITION FOULED CLEAN CLEAN FOULED
UA W/°C 60233 65941 77492 58353
TOTAL HOT FEED
KG/HR 49344 49344 49344 49344
STRM 13
BYPASS
KG/HR 15968 17110 26748 26013
STRM 14-B
COLD FEED
KG/HR 61772 61772 61772 61772
STRM 132
HOTSIDE-IN
°C 115.3 115.3 110.7 110.7
STRM 13-C
HOT SIDE- OUT
°C 62.5 32.1 24.3 26.9
STRM 14-A
COLD SIDE- IN-
°C 23 23 23 23
STRM 132
COLD SIDE- OUT
°C 60 60 50 50
STRM 133
E-30502
CASE A B C D
HX CONDITION FOULED CLEAN CLEAN FOULED
UA W/°C 63517 96913 96913 63517
TOTAL HOT FEED
KG/HR 49344 49344 49344 49344
STRM 11
BYPASS
KG/HR 13667 20866 19654 11172
STRM 13-B
COLD FEED
KG/HR 30529 30529 30742 30742
STRM 9-A
HOTSIDE-IN
°C 171.1 171.1 171.1 171.1
STRM 11-A
HOT SIDE- OUT
°C 92.3 70.7 66.9 91.7
STRM 13-A
COLD SIDE- IN
°C 54.4 54.4 47.6 47.6
STRM 9-A
COLD SIDE- OUT
°C 141 141 141 141
STRM 9
E-30504
HOTSIDE-IN
°C 62.6 62.5 72.9 72.7
STRM 14
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A: Exchanger E-30501
30501 & E30502 fouled condition;
condition E-30501 cold side outlet at 60°C

B: Exchanger E-30501
30501 & E30502 clean condition; E-30501
E cold side outlet at 60°C

C: Exchanger E-30501 & E30502 clean condition; E-30501

E cold side outlet at 50°C

D: Exchanger E-30501
30501 & E30502 fouled condition; E-30501
E cold side outlet at 50°C

During the normal operation, it can be observed that the maximum process temperature
inlet to crude oil cooler is at 73.0°C only.

With 8°C approach is considered with crude oil cooler, the rundown temperature is a
direct function of the ambient air temperature.

2.2 Limitation of TVP Specification

pecification to Floating Roof Tanks:
Although there are evidence, that floating roof can safely
s operate up to the actual TVP of
13 psia [Ref 1],
], it is common practice to reduce the TVP to less than 11.1 psia for storing
in to floating roof tanks as recommended by US EPA [Ref
[ 2].
]. The following figure, provides
the actual TVP for crude oil at various rundown temperatures.

Crude Vapor Pressure

16

15
Crude Vapor Pressure , PSIA

14

13 TVP at 50°C
TVP at 48°C
12
TVP at 45°C
11
TVP at 42°C
10 TVP at 40°C
9

8
8 8.5 9 9.5 10 10.5 11
Stabilised Crude TVP at 37.8°C
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It is evident from the above chart, that the acceptable limit on TVP for floating roof tanks
[11.1 psia @ crude oil storage temperature] cannot be achieved at the present level of
crude oil stabilisation with the design rundown temperature at 48°C.. Hence a further
analysis is carried out in following directions, to meet the acceptable limit on TVP for the
floating roof tanks.

1. Establish the period during which the maximum peak ambient nt temperature is
possible. This will ensure that the plant operation
operation can be planned for any change
with level of stabilisation in advance.

2. Identify the potential bottlenecks in the plant design to meet the stringent
stabilisation specification during the peak ambient temperature.

3. At the worst case, identify the extent of plant load reduction envisaged during the
period of peak ambient temperature occurrence.

2.3 Meteorological Data

ata on Ambient Air Temperature
From the final DIA report issued for this project, the following table of average maximum
temperature in the study area from 1992 to 2002 is indicated below. [RefRef 3
3].

Year Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Mean
°C °C °C °C °C °C °C °C °C °C °C °C °C
1992 30.0 31.4 30.3 30.5 29.2 27.6 26.5 25.9 26.6 27.3 30.4 29.8 28.8
1993 30.0 31.0 31.5 30.1 29.8 28.3 27.3 26.5 28.1 29.1 31.5 30.1 29.4
1994 29.8 30.7 29.7 30.3 29.7 28.3 26.3 27.0 27.1 28.0 31.5 30.4 29.1
1995 30.8 31.6 30.9 30.8 30.0 28.2 26.8 27.4 28.0 28.4 32.5 30.0 29.6
1996 30.2 30.8 30.2 30.9 30.6 28.8 27.8 27.0 27.3 28.1 29.8 30.2 30.2
1997 30.3 31.4 30.7 30.0 29.5 28.3 27.7 27.0 28.1 29.1 29.6 30.5 29.4
1998 31.0 32.8 32.6 31.9 31.0 30.0 28.4 27.8 27.8 28.3 29.8 30.1 30.1
1999 30.2 30.6 30.5 30.0 29.6 28.9 27.9 28.0 26.7 27.3 28.9 30.2 29.0
2000 30.3 31.1 31.3 30.3 30.0 28.7 27.8 26.8 26.7 28.0 29.2 30.2 29.2
2001 30.6 31.5 30.4 30.1 29.6 28.6 27.3 26.7 27.4 28.8 29.4 30.5 29.3
2002 31.0 31.5 30.4 30.7 30.7 28.8 28.1 27.3 27.9 28.1 29.6 30.2 29.5
Mean 30.4 31.3 30.8 30.5 30.0 28.6 27.5 27.0 27.4 28.2 30.2 30.2 29.3
Min 29.8 30.6 29.7 30.0 29.2 27.6 26.3 25.9 26.6 27.3 28.9 29.9 28.8
Max 31.0 32.8 32.6 31.9 31.0 30.0 28.4 28.0 28.1 29.1 32.5 30.5 30.2

From the above table, it can be observed that the monthly average maximum ambient
temperature has not exceeded more than 33°C during the study period. However, based
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on further web search, it is observed that the maximum peak temperature of 37°C is
possible in the coastal areas in the south of
o Nigeria. [Ref 4].

2.4 Expected Crude Oil

il Temperature during the Maximum Ambient C
Conditions
It is observed that the peak ambient temperature is predominantly possible during the
months of February, March
arch and April.
pril. During these periods, at an average, it is expected
that these peak temperature can be sustained for 4 hours in the day time. This works out
to be around 4% of the total time in a year.

With the peak average temperature being high at 33°C for the rest of the day, considering
the crude oil cooler being designed to get minimum 8°C approach in temperature, the
expected crude oil rundown temperature is 41°C. This will well within the acceptable
limit on the TVP for floating roof tanks.

Considering around 4%% of the time in a year, the ambient temperature may be high at
40°C, the following were checked.

1. The possible crude oil rundown temperature with the present design margin
considered for the crude oil cooler.

2. Required level of crude oil stabilisation to meet the acceptable TVP specification
for floating roof tanks during these peak ambient temperature period of 4 hours.

2.4.1 Crude Oil Rundown

undown with the Present Available Air Cooler Design
esign Margin
It is observed that with the crude oil air cooler design (with margin) it is possible that the
crude oil can be cooled up to 46.7°C,, when the ambient air temperature is at 40°C. From
figure 2 - TVP sensitivity chart, it can be observed that to meet the acceptable TVP for
floating roof tanks, the crude oil shall be stabilised to at least 8.7 psia @ 37.8°C.

Process parameters envisaged to meet the required TVP at tank during the peak ambient
conditions.
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Table -2.2
2.2 , Comparison Table

Expected Operating
Normal Operating conditions to meet Expected increase
condition stringent Stabilisation in process data
Specification %

Stabilised Oil TVP at 37.8°C 10 psia 8.7 psia

E-30501
Cold feed Flowrate ,kg/h 61772 62065
Hot Feed Flowrate ,kg/h 49344 49384
Hot Side Temperature IN , °C 110.7 112.9
Hot Side Temperature OUT , °C 72.9 75
Duty , KW 1246 1251 0.40
E-30502
Cold feed Flowrate ,kg/h 30666 30823
Temperature IN , °C 47.4 47.4
Temperature OUT , °C 141.1 147.4
Hot Feed Flowrate ,kg/h 49344 49384
Temperature IN , °C 171.1 177.4
Temperature OUT , °C 110.7 112.9
Duty , KW 2162 2330 7.8
H-30401 , Reboiler
Temperature IN , °C 171.1 177.4
Temperature OUT , °C 201.7 209
Duty , KW 2178 2278 4.6
A-40101A/B,
Booster Compressor Package
Flowrate ,kg/h 4304 4560

Booster Compressor Duty , KW 283.5 293.8 3.6

It should be noted that 10% design margin is included in CPF Equipment design and the
process conditions required to meet TVP of 8.7 psia @ 37.8°C can be easily achieved with
current CPF equipment design margin.
margin
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3 CONCLUSION
It can be observed through this technical note, the following,

1. There is no need
eed to improve on level of stabilisation of crude oil over to the
present design specification,
specification to meet the acceptable limit of TVP for crude oil
storage tanks for most of the time. It is possible to get the required crude oil
storage temperature during most of the period based on the maximum average
ambient temperature of 33°C.

2. Even during the short period of time, when the ambient temperature can be as
high as 40°C, with the equipment
equipment design margin with stabiliser, booster
compressor, stabiliser reboiler, feed product exchangers and crude oil air cooler, it
is possible to improve on the level of stabilisation in stabiliser to meet the required
TVP for floating roof tanks. The stabiliser base temperature of 177°C is envisaged
during this short term operation.
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4 REFEENCES
1. W.L Nelson, Petroleum Refinery Engineering, Fig-256
Fig

2. Environmental Protection Agency - 40CFR60 - PART 60_STANDARDS OF

PERFORMANCE FOR NEW STATIONARY SOURCES

3. Table 4.5, Final EIA Report of Stubb Creek Marginal

Marginal Field Development Project

4. General
eneral information about Nigeria and its climate.
http://www.canuk.org.uk/aboutnigeria.aspx