EGP H2S SOLID BED

SCAVENGER PROJECT

CONTROL AND SAFETY PHILOSOPHY

 
Contract No: XXX
Work Authorization: XXX
EGP-E041-ICS-PHL-CNL-0000-90001-00
 

 
G01 18-Jan-21 Issued for Design LCFK LCFK I.OJOBOH
REV DATE ISSUE PURPOSE ORIG CHK APPR

APPROVED BY: COMPANY APPROVAL:

DATE DATE:

Document Control No. Project Area Discipline Type Originator Package Sequence-Sht Revision

EGP E041 ICS PHL CNL 0000 90001-00 G01

EGP H2S Solid Bed Scavenger Project EGP-E041-ICS-PHL-CNL-0000-90001-00
CONTROL AND SAFETY PHILOSOPHY Revision: G01

REVISION HISTORY
Revision Date Description Remarks

HOLD’s

1. Frequency of the Solid Bed Change over

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EGP H2S Solid Bed Scavenger Project EGP-E041-ICS-PHL-CNL-0000-90001-00
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1 Contents
2  INTRODUCTION / PROJECT OVERVIEW ........................................................................................ 4 
3  REFERENCES ................................................................................................................................... 4 
4  ABBREVIATION ................................................................................................................................ 5 
5  CODES, REGULATIONS AND SPECIFICATIONS ........................................................................... 7 
5.1  Legislation and Regulations ........................................................................................................ 7 
5.2  Engineering Standards and Specifications ................................................................................. 7 
5.2.1  COMPANY Standards ......................................................................................................... 7 
5.2.2  Industry Codes, Specifications and Practices...................................................................... 8 
6  PROCESS DESCRIPTION ................................................................................................................ 8 
6.1  H2S Solid Bed Scavenger – New Installation ............................................................................. 8 
7  H2S SOLID BED SCAVENGER UNIT PROCESS DESIGN .............................................................. 9 
7.1  Design Capacity .......................................................................................................................... 9 
7.2  Feed Stream Properties .............................................................................................................. 9 
7.3  Inlet Heater ................................................................................................................................. 9 
7.4  Product Specification ................................................................................................................ 10 
8  UNITS OF MEASUREMENT............................................................................................................ 10 
9  PHILOSOPHY OF DESIGN ............................................................................................................. 10 
9.1  Overview ................................................................................................................................... 10 
9.2  Instrumentation, control and safety ........................................................................................... 10 

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2 INTRODUCTION / PROJECT OVERVIEW

EGP Train 1 & 2, which supplies gas to EGTL, was designed for sweet gas. In recent times, H2S content
of the gas supply to EGTL had occasionally exceeded the spec (5 ppmv). This is due to the feed gas to
Train 1 experiencing reservoir souring.
Souring study of selected facilities by ETC predicted an average of 6 – 10 ppmv H2S in gas to EGP for
the next 10 – 12 years which exceeds sales gas agreement. Higher H2S content in the feed gas to EGP
have been resulting in:
– Off-spec sales gas, exceeding Total Sulphur Content design threshold of 3 ppmv.
– LPG from Train 1 and Condensate stabilization system has frequently failed the Copper
Corrosion Test (> 1b)

Based on “Escravos Souring Study & EGP H2S Mitigation” analysis; carried by ETC; H2S forecast for the
Train 1 inlet to Escravos Gas Plant predicts the peak H2S level of 20 ppmv to ~ 40 ppmv in next 20 to 30
years respectively.

Two main mitigation alternatives were considered:

– Treatment of injected produced water
o Nitrate Treatment
o Sulphate Removal Membranes
– Treatment of gas into the Gas Plant
o Liquid scavenger injection
o Liquid scavenger Contactor
o Solid bed scavenger
A centralized treatment of incoming AG at EGP, with solid scavengers (with lead-lag beds) was
recommended over a liquid scavenger contact tower for the following reasons:
– It has lower Opex and Capex
– It has lower footprint
– Entails less piping modifications and hydraulic concerns

The scope of the project includes provision of H2S solid bed scavenger vessels, installed in the feed line
to the EGP Train 1 to remove all incoming H2S to the plant and H2S sloid bed scavenger system
integration into EGP operation.

3 REFERENCES

S/No Document No Description

1 N/A Escravos Souring Study & EGP H2S
Mitigation ; done by ETC; Dated: Sep 2014
2 Drawing No 55-076.GSP.PI.10-701045-000 Gas Plant Filter Separator
3 DOCUMENT NO. ONS-HHI-GP-DES-PR- EGP Basis of Design
0002

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4 ABBREVIATION

Abbreviation Description
AG Associated Gas

AISC American Industry of Steel Construction

ANSI American National Standards Institute

API American Petroleum Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers

ASTM American Society of Testing and Material

AWS American Welding Society

BoD Basis of Design

BPD Barrels Per Day

CES Chevron Engineering Standards

CNL Chevron Nigeria Limited
COMPANY Chevron Nigeria Limited
COS Carbonyl Sulphide
DED Detailed Engineering Design
DNV Det Norske Veritas
DPR Department of Petroleum Resources
EGP Escravos Gas Plant
EGASPIN Environmental Guidelines and Standards for Petroleum Industry in Nigeria
EGTL Escravos Gas To Liquids
ELPS Escravos Lagos Pipeline System
ETC Engineering Technical Company
FGS Fire and Gas Detection and Suppression System
FEED Front End Engineering Design

H2S Hydrogen Sulphide

HES Health, Environment and Safety

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ICS Integrated Control System

IEC International Electrotechnical Commission
ISA Instrumentation Systems and Automation Society
ISO International Organization for Standardization
LAT Lowest Astronomical Tide
LCP Local Control Panel
LPG Liquified Petroleum Gas
MAOP Maximum Allowable Operating Pressure
MCP Master Control Panel
MMSCFD Millions Standard Cubic Feet per Day
MP Medium Pressure
MSm³ Million Standard cubic meters
MSS Manufacturers Standardization Society
NACE National Association of Corrosion Engineers
NAG Non-Associated Gas
NAPIMS National Petroleum Investment Management Services
NGL Natural Gas Liquid
NFPA National Fire Protection Agency
NPA Nigerian Ports Authority
OPEX Operational Expenditure
PCS Process Control System
PIP Process Industry Practices
SI Systeme International d'Unites (International System of Units, or metric system)
SID Safety in Design
SIL Safety Integrated Level
SIS Safety Instrumented System
SOP Standard Operating Procedures

SSS Safety Shutdown System

TEG Triethylene Glycol
UOP Universal Oil Product

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5 CODES, REGULATIONS AND SPECIFICATIONS

All aspects of the design and installation work are to comply with the requirements of Nigeria regulations,
international codes and standards, Company Standard Operating Procedures, and specifications.
Engineering efforts and design shall utilize the most recent versions of codes, standards, SOPs, and
recommended practices issued by Company, industry associations and regulatory bodies listed in this
specification. The order of precedence is as listed below:

– Applicable Nigerian Laws, Regulations, Acts and their amendments

– Project Specifications
– CES
– International Industry Codes and Standards

Any conflict or discrepancy between this document or Company specifications and applicable industry
codes or standards or recommended practices and/or Nigerian regulations shall be submitted in writing
along with a proposed resolution to Company for final resolution.

5.1 Legislation and Regulations

Nigerian legislation and regulations ruling the Nigerian oil and gas industry are mandatory and shall be
considered in the engineering design where applicable.
The H2S Solid bed Scavenger Design must be compliant with DPR and other applicable Nigerian
regulations. Following is a partial list of Nigerian regulatory bodies which require interface with the project:
 National Petroleum Investment Management Services (NAPIMS)
 Department of Petroleum Resources (DPR)
 Nigerian Content Development Monitoring Board (NCDMB)
 Nigerian Port Authority (NPA)
 Federal Environment Protection Agency
 Federal Ministry of Environment

Following is a list of applicable Nigerian regulations ruling oil and gas industry (list not exhaustive):
 Nigerian Oil and Gas Industry Content Development Bill, 2010
 Coastal and Inland Shipping (Sabotage) Act
 Niger Delta Development Commission
 Oils in Navigable Waters Act
 The Mineral Oils (Safety) Regulation
 Petroleum Act
 Oil Pipelines Act
 Petroleum Drilling and Production Act
 Crude Oil (transportation and Shipment) Regulations

5.2 Engineering Standards and Specifications

5.2.1 COMPANY Standards

Chevron Engineering Standards (CES) are to be applied, as relevant

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5.2.2 Industry Codes, Specifications and Practices

Engineering design shall be in accordance with applicable International Codes, Standards or
Recommended Practices in conjunction with CES Specifications.
International Codes issued by following organizations should be used as reference where applicable (list
not exhaustive):
 American Petroleum Institute (API)
 American National Standards Institute (ANSI)
 National Fire Protection Agency (NFPA)
 American Society of Mechanical Engineers (ASME)
 International Organization for Standardization (ISO)
 American Society of Testing and Material (ASTM)
 American Welding Society (AWS)
 American Industry of Steel Construction (AISC)
 Process Industry Practices (PIP)
 Det Norske Veritas (DNV)
 International Electrical Commission (IEC)
 National Association of Corrosion Engineers (NACE)
 Instrumentation, Systems, and Automation Society (ISA)
 National Electrical Manufacturers Association (NEMA)
 Manufacturers Standardization Society (MSS)
 American Society of Civil Engineers (ASCE)
Industry codes, specifications and recommended practices called by this document shall be used and
followed for engineering design.

6 PROCESS DESCRIPTION

6.1 H2S Solid Bed Scavenger – New Installation

The incoming gas to Train 1 is fed to the newly added H2S Solid Bed Scavenger Unit to adsorb the H2S
from the feed.

Prior to sweetening by H2S Solid Bed Scavenger Unit, filter separators will remove any entrained or
condensed liquids in the gas stream.

The design capacity of the H2S Solid Bed Scavenger Unit shall be 318000 Nm3/hr (285 MMSCFD), in line
with Train 1 design capacity.

The H2S Solid Bed Scavenger unit comprises two vessels with Lead/Lag arrangement. Each vessel,
however, shall be designed to meet the gas specification at full design capacity, when the bed is fresh.
Over the time, when the bed is partially saturated and the gas specification is not met at the outlet of the
vessel, the second vessel is brought to the services, in series with the first vessel. This is to utilize the
whole bed adsorption capacity in each vessel.

The H2S Solid Bed Unit shall be designed for normal operation with feed gas H2S content of 20 ppmv from
the incoming pipelines. The treated gas H2S specification is 0 ppmv.

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The H2S Solid Bed Unit shall be designed with a feed gas H2S content of 40 ppmv (based on H2S content
level in feed gas at Year 2050+). However, the design requirement is achieved by considering two vessels
are operated in parallel. Moreover, a provision shall be made for future tie-in the third vessel of H2S Solid
Bed Scavenger to achieve the design specification, during high H2S content operation.

The solid bed material in the vessel shall be suitable for the service and compatible for the feedstock
compositions. The bed material shall be selected as such to avoid any side reaction among the feedstock
composition. Moreover, no gas composition(s) other than H2S shall be adsorbed by the selected bed
material. The solid bed supplier shall define the appropriate material for the solid bed.

After the gas has been sweetened and H2S has been removed via the solid bed scavenger, it is filtered
through a cartrige filter (2 x 100% - Duty/Spare) to minimize the potential for solid bed dust fouling the
downstream Molecualr Sieve in the Dehydration Unit.

The gas from the H2S Solid Bed Scavenger Unit is routed to the Molecular Sieve / Dehydration System
for Dehydration and gas drying process.

As part of the H2S Solid Bed Scavenger Unit Project, the Train1-Train 2 interconnecting piping is
relocated to downstream of the H2S Solid Bed Scavenger Unit to ensure Train 1 feedstock gas is treated
through the H2S Solid Bed Scavenger to reduce the H2S content, prior diverting to Train 2.

7 H2S SOLID BED SCAVENGER UNIT PROCESS DESIGN

7.1 Design Capacity

Design capacity of the H2S Solid Bed Scavenger Unit shall be 285 MMSCFD, the same as Train 1
design Capacity. The unit comprises one Shell & Tube heat exchanger, two vessels, each shall be
designed for 100% design capacity.

There are two cartridge filters downstream of the scavenger vessels. The filters are 2 x 100%
arrangement and they shall be designed for 100% design capacity.

7.2 Feed Stream Properties

The design H2S level in the feed stream shall be considered 20 ppmv. However, the H2S level exceeds
20 ppmv from year 2040 and reaches about 40 ppmv in year 2050, and tie-in shall be provisioned for
additional vessel (third vessel) to cater the high H2S level feedstock.
The operating pressure & temperature are 61.4 bara & 35.0 oC respectively.

7.3 Inlet Heater

The phase envelope of the inlet feed stream to the H2S Scavenger Solid Bed shows there is a chance of
retrograde condensation across the bed, due to pressure drop across the H2S scavenger solid beds.
The condensate retrograde generation across the bed leads to the premature bed saturation with loss of
H2S adsorption capacity for the facilities.

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The feed stream to the H2S Scavenger solid bed is required to be superheated by 5 oC, through the
newly added shell & tube heat exchanger.

The shell & tube heat exchanger uses the hot oil flow as heating medium.

7.4 Product Specification

The H2S Solid Bed Scavenger Unit shall be designed to reduce the H2S level at the gas outlet to 0 ppmv.
This shall be the basis for each vessel sizing in the unit.

However, the vessel solid bed shall be replaced, when the H2S level at gas outlet from the Solid Bed
Scavenger Unit reached 3 ppmv.

It is noted than partially dissolved H2S in the liquid phase of the Condensate in the Train 1 Slug catcher will be
released in MP Separator. The gas is liberated in the MP separator and comingled with lean gas from Train 2
which is also a make-up gas supply source to EGTL. The simulation shows that the gas released from
condensate in MP Separator; from the maximum condensate production rates of 8345 bbl/day from Okan
GGCP, Meji GGCP and Abiteye NAG; results in an increment of 1.3 ppmv H2S concentration in the Gas to
EGTL, when the H2S level in the Feed gas to Train 1 approaches 40 ppmv.

8 UNITS OF MEASUREMENT
Systeme International d'Unites or SI (International System of Units) shall be used as specified in CES-
GEN-SU-5227 - Units of measurement. To assist in clarity, Imperial system shall be shown parenthetically
for piping and pipeline; and may be discretionally used by others disciplines (also shown in parenthesis).

9 PHILOSOPHY OF DESIGN

9.1 Overview
Chevron Engineering Standards (CES) and CNL drafting guidelines shall be followed for the design.
Where it is indicated that no modifications to aspects of the existing facilities PCS, SSS & FGS, etc.,
other than the integration of the skid instrumentation extensions required under the project scope, are
envisaged, during site visits or Detail Engineering Design modifications outside of the normal expected
scope become evident then the BoD shall be updated to reflect these new requirements.

9.2 Instrumentation, control and safety

The EGP control system includes distributed control system (DCS) system. The DCS will enable
continuous monitoring and control of the gas plant process systems by operations from a central console
located in the control room.

The H2S Solid Bed Scavenger Unit control & shutdown instrumentation shall be integrated into the EGP
DCS & SIS Systems. Separate junction boxes will be provided to collect all signals to the DCS/SIS
systems.

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Hot oil from the gas plant is passed through Scavenger Bed Inlet heater 2-E-6030 Flow control loop
regulates the flow at xxxx bbls/day (hold); a temperature controller in cascade will adjust flow to maintain
a temperature of xxx Deg C for the hot oil.

A cascade flow control loop controls valve FV-6030 to regulate the hot oil flow through the H2S adsorber
superheater 2-E-6030A/B based on Differential temperature of inlet and outlet gas.

Blowdown valves are preliminarily considered on each scavenger bed to relief inventory in case of any
emergency condition.

Heated gas is sent to H2S Scavenger Beds to sweetened the gas. An H2S analyzer AIT-4303 installed
after the Wet Gas Solid filters F-4303A/B will monitor H2S content in the gas and will provide an alarm to
the operator on control room in case of any deviation. Flow control valve FV-8330 installed in the by-pass
line of H2S Adsorber units, will regulate gas flow through H2S Scavenger Beds based on H2S
concentration measured by AIT-4303

Adequate F&G detection instrumentation is provided around the H2S scavenger unit, F&G detection is
integrated into the EGP F&G system through a 4-20 ma signals.

Alarm and trip settings shall be defined for set of Fire & Gas Detectors, as per the EGP Alarm &
shutdown setting criteria during DED.

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