1063 FD TR 00 00 PS BD 0016 03

Aban & West Paydar Oil Field Development Project
(FEED, Detailed Design of Earthworks &

Foundations, and Detailed Design Supervision)
Title:
Process Description
Document No.: Class: 3

Page 1 of 15
1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
Process Description
03 27-Sep-20 Issued for Information H.Ghods H.Ebrahimi A. Zamani

02 7-Jan-19 Issued for Information H.Ghods H.Ebrahimi A. Zamani
01 23-Dec-19 Issued for Information H.Ghods H.Ebrahimi A. Zamani
00 9-Jun-19 Issued for Information N.Sarkari H.Ebrahimi A. Zamani
Rev. Issue Date Purpose of Issue Prepared Checked Approved Client Approval
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
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Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
Table of Content
1. INTRODUCTION .................................................................................................................................... 4
1.1. PURPOSE .................................................................................................................................................. 4
1.2. DEFINITIONS ......................................................................................................................................... 4
2. PROJECT DESCRIPTION AND SCOPE OF WORK ............................................................................. 4
3. CODE AND STANDARDS ....................................................................................................................... 5
4. REFERENCE DOCUMENTS ................................................................................................................. 5
5. ABBREVIATIONS .................................................................................................................................... 5
6. PROCESS DESCRIPTION ....................................................................................................................... 5
6.1. WELLHEAD FACILITIES ....................................................................................................................... 6
6.2. AGMU ........................................................................................................................................................ 7
6.3. FREE WATER KNOCK OUT PACKAGE (FWKOP) .............................................................................. 7
6.4. CRUDE TRANSPORTATION ............................................................................................................... 12
6.5. CHESHMEN-KHOSH CPF ................................................................................................................... 13
6.6. REPAIR OF BANK D .............................................................................................................................. 13
6.7. UPGRADE OF TEST LINE ................................................................................................................... 13
6.8. CRUDE OIL METERING AT CCTMU ................................................................................................. 13
6.9. CHEMICAL AND ANALYTICAL LABORATORY .............................................................................. 14
7. UTILITIES .............................................................................................................................................. 14
7.1 FUEL GAS ............................................................................................................................................... 14
7.2 INSTRUMENT AIR /PLANT AIR ........................................................................................................ 14
7.3 FLARING SYSTEM ................................................................................................................................ 15
7.4 BURN PIT ............................................................................................................................................... 15
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
1. INTRODUCTION
1.1. Purpose
This document explains the process and utility facilities of the Aban & West Paydar Oil Field Development
Project.
1.2. Definitions
PROJECT Aban & West Paydar Oil Field Development Project (FEED, Detailed
Design of Earthworks & Foundations, and Detailed Design Supervision)
CLIENT/OWNER ZN-Vostok Ltd.

CONTRACTOR Tehran Raymand Consulting Engineers (TRCE)
EPC Any firm who is responsible for providing any service and material with
respect to detailed engineering, procurement, construction of all items and
material in accordance with the contract between the CLIENT and him
FEED Front End Engineering Design

PURCHASER Any firm who buy services, material and/or equipment for execution of
the project within a dedicated contract.
SUPPLIER Any vendor, manufacturer who supply any Service, Material or
Equipment for the project
SHALL Refer to a mandatory requirement
SHOULD Refer to a recommendation
MAY Refer to one acceptable course of action
2. PROJECT DESCRIPTION AND SCOPE OF WORK
Aban and West Paydar oilfields are located in the western part of Iran, on the Iran-Iraq border. Development
and production operations service contract (IPC) for Aban and West Paydar oilfields between National Iranian
Oil Company (NIOC), ZN Vostok Ltd and Dana Energy was signed on March 14, 2018. The project objective
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
is to prepare FEED Package, Detailed Design of earthworks and foundations, Field Supervision of earthworks
and foundations and Supervision of Detailed Design documentation of relevant subcontractors
3. CODE AND STANDARDS
N.A
4. REFERENCE DOCUMENTS
Process Flow Diagram West Paydar FWKOP 1063-FD-TR-00-00-PS-PF-0001
Process Flow Diagram Aban FWKOP 1063-FD-TR-00-00-PS-PF-0002
5. ABBREVIATIONS
CPF: Central Processing Facilities

SSV: Surface Safety Valves
SSSV: Sub-Surface Safety Valves
ESD: Emergency Shut-Down
RTU: Remote Terminal Unit
LBV: Line Break Valve
ESDV: Emergency shutdown/isolating valves
SCADA: Supervisory Control & Data Acquisition
AGMU: Automated Group Metering Unit
FWKOP: Free Water Knock Out Plant
ESP: Electrical Submersible Pump
6. PROCESS DESCRIPTION
Each Aban and West Paydar oilfield includes the following:

 Wellhead Facilities
 AGMUs
 FWKOP
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
6.1. Wellhead Facilities
Wellhead facilities for wells consist of the following utilities and equipment. Due to decreasing pressure and
expectancy of increasing reservoir free water, it’s required to consider Electrical submersible pumps (ESP) to
pressurize existing wells reservoir multiphase fluid to enhance oil production.
6.1.1. Aban Wells infrastructure
Two categories are considered for Aban wells:

a) Shifting of existing 9 wells to production with 9 ESP pumps. Existing wells contains:
 ESP control station and outdoor power panel for pumps
 Power supply network
 Lightening and Grounding protection
[Deleted]
Two new wells are also to be drilled.
6.1.2. West Paydar Wells infrastructure
Four categories are considered for West Paydar wells:

a) Shifting of 28 existing wells to production with 28 ESP pumps contains:
 ESP control station and outdoor power panel for pumps
b) Six new single wellheads contain:
 Choke valves
 Burn pit
 Wellhead control panel
 Emergency Shutdown system valves and instrumentation
 Chemical injection system
 Flow lines from wells to gathering unit
c) Shifting of existing 6 production wells to water injection wells.
These wells contain:
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03

6.2. AGMU
The supplied well fluids above ground flow lines will be gathered in two headers (manifold), the AGMU
manifold and main manifold. Since monitoring of oil, gas and water contents is essential to integrated reservoir
management, an automated group-metering unit including of two phase separator and flow meters for liquid
and gas lines are considered on manifold area to test of each well. Reservoir fluid can be routed to main manifold
and transfer to free water knock out package unit thru existing above ground flowlines for further treatment.
Four AGMUs for West Paydar field (three for Asmari sweet oil wells and one for Sarvak sour oil wells) and one
AGMU for Aban field (Asmari sweet oil wells) are considered.
Emergency shutdown/isolating valves (ESDV) is considered for each flow line at the manifold area as part of
existing facilities.
6.3. Free Water Knock Out Package (FWKOP)
Reservoir fluid from wellheads is routed to existing manifold area by flow lines. Considering production profile
of West Paydar field reported in pre-FEED report, high produced water content in each field well stream are
presented. One of key requirements of project is to limit produced water content at delivery point (Cheshmeh
Khosh CPF) to 5% water cut. This critical item leads project to have pre-separation at fields to decrease water
content of oil up to maximum limit. To separate excess produced water, it is intended to construct WP FWKOP.
Pre-separation at new FWKOP helps to meet contractual requirements for limitation of produced water content
in well fluid. Aban manifold will be upgraded to send liquid (oil plus water) to Cheshmeh-khosh.
After pre-dehydration at FWKOP well fluid with max 5% residual water cut will be transported to Cheshmeh-
Khosh CPF.
The main productive formations of West Paydar are the Oligocene-Miocene Asmari formation and Cenomanian
Sarvak formation. Both formations are in development. Oil composition of Sarvak formation is sour so two
trains will perform water separation.
The main production of Aban field is related to Oligocene-Miocene Asmari formation and separation of this
field will be performed in one train.
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
All existing facilities will be studied to maximum usage of them with considering forecast for Aban and West
Paydar well fluid oil and water production.
At Aban manifold, no water separation is performed.
Process Description of West Paydar field is as follows:
Asmari gas-saturated water/oil emulsion flows to inlet of first stage three phase separators’ for crude degassing
and dehydration.
Partially degassed oil routed to the indirect fired heaters (Water Bath) where it warms up in winter condition to
reach better separation of water content. The fluid then flows to 2nd stage three-phase separators, where
dissolved gas is released and oil is further dehydrated.
Gas from first and second separation stages flows to KO drum and then mixed with dehydrated oil flow for
further transport by multi-phase pumps to Cheshme-Khosh CPF.
Dehydrated oil (residual water cut 5 % mass) downstream 2nd stage three-phase separators is mixed with gas
flow and comes to the inlet header of new export Multi phase pumps.
Water from three-phase separators is discharged in buffer-degassers, then (for additional settling) water comes
to integrated water treatment system and then to water injection pumps’ suction for further injection in
dedicated injection wells.
Drains from pressure equipment, pipe gas expander and pump equipment are routed to U/G buried drain drum
which equipped with two semi-submersible pump units to transfer the accumulated drains back to the process.
Sarvak partially degassed oil downstream existing oil/gas separators flows to line heater (one set), where it is
heated to temperature (54 degC) required for better removal of inlet water. Downstream the line heater oil flows
to three-phase separator (second stage), where remained dissolved gas is released and oil is dehydrated.
Dehydrated oil (residual water cut 5 % mass) then comes to the inlet header of export pumps.
Four start-up complex has been defined and equipment of FWKOP unit will be procured and installed partially
based on defined required capacity of each complex.
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
Process Description of Aban field is as follows:
Gas-saturated water/crude emulsion from Aban wells flows to Aban manifold/FWKOP inlet into existing oil
and gas separator for crude degassing.
Then degassed crude flows to inlet header of export pumps for transferring thru existing pipeline to CPF
Cheshme-Khosh.
Separated gas from first-stage separation routed to KO drum (Gas expander) and is burnt in flare. Equipment
drains, including pipe gas expander drains (Flare K.O Drum), flow to U/G Drain drum with two semi-
submersible pump units. [Deleted]
[Deleted]
[Deleted]
Gas from KO drum flows to gas the flare package. A part of gas is used as fuel for Flare/Burn pit pilot burners.
In case of emergency gas will be discharged from process equipment to the flare.
Flare system includes Flare Stack and Flare KO drum.
The liquid (Oil+Water) after pressurizing by transfer pumps will be sent to Cheshmeh Khosh facility via existing
aboveground pipe line. A custody transfer metering station shall measure the quantity of the exported crude oil.
In order to bypass pump station, second mode of operation is defined as existing separator operating pressure
is increased to 57 barg. In this case level of the drum will be controlled by dedicated LCV.
The Mobile launching and receiving facilities is considered for this pipeline.
6.3.1. West Paydar FWKOP facilities commissioning levels
Four start-up complexes were singled out for West Paydar FWKOP facilities commissioning start.
Based on the obtained dynamics of oily liquid production levels, maximum performance of West Paydar
FWKOP were determined for each start-up complex.
Start-up Complex I
It is expected to use existing gathering and transport system to CPF without water pre-
separation during start-up complex I operation – to transport Sarvak well stream.
Title:
Process Description

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Asmari crude to be treated at FWKOP during start-up complex I operation using the following
equipment:
 Oil and gas separator, (4-PV-01 A/B)
 Three-phase separator, (4-PV-02 A/B)

 Knock out drum, (4-PV-05)
 Existing oil and gas separators for Sarvak, (4-PV-03 A/B)

 Existing MPP multiphase pump, (4-P-01 A/B)
 Flare Package, (4-FST-01)
 Pipe gas expander (Flare K.O. Drum), (4-PV-08)

 Drain vessel, (4-D-01 )
 Semi-submersible pumps, (4-SP-01 A/B)
 Buffer-degasser, (4-PV-09 A)
 Water Injection Pumps, (4-P-03 A/B/C/D)
 Demulsifier Injection Package; (4-CIU-01)
 Corrosion inhibitor Package (4-CIU-02)

Gas-saturated water/crude emulsion from West Paydar Asmari wells flows to FWKOP inlet in
oil and gas separators for crude degassing.
Partially degassed crude flows to second-stage separation to three-phase separators for
degassing and dehydration.
Gas of the first and second separation stages flows to KO drum and to flare.
Start-up Complex II
The following equipment is additionally required during start-up complex II operation to treat
Asmari and Sarvak crude oil separately:
 Water treatment plant – steel vertical tank, (4-TK-01)
 Crude return pump, (4-P-04 A/B)
 Three-phase separator, (4-PV-02 C/D)

 Centrifugal pumps for Sarvak and Asmari crude transportation, (4-P-02 A/B/C/D)
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
 Heater with intermediate heat carrier for Asmari line,(4-HT-02 A/B/C)

Gas-saturated water/crude emulsion from West Paydar Sarvak wells flows to existing oil and
gas separators’ inlet for crude degassing. Gas from first, second-stage separations flows to KO
drum and then to flare. It is possible to transport gas partly from the Asmari or Sarvak
formations through an 8” pipeline to CPF.
Degassed Sarvak crude is transported to CPF by existing multiphase pumps or export
centrifugal pumps.
Degassed and dehydrated Asmari crude flows to inlet header of existing multiphase pumps and
can be also transported to CPF by export centrifugal pumps.
Separated water from Asmari/Sarvak separators will be treated in water treatment vessels/tank
and will be injected to the water injection wells.
Start-up Complex III

The following equipment is additionally required since start-up complex III operation beginning
to treat Asmari and Sarvak crude oil separately:
 Heater with intermediate heat carrier for Sarvak line,(4-HT-01 )
 Three-phase separator for Sarvak line, (4-PV-04 )
 Buffer-degasser, (4-PV-09 B)
 Discharge Scrubber (Terminal separator, (4-PV-07)
Partially degassed Sarvak crude from existing oil and gas separators flows to heat tracer, where it
is heated to temperature required for water/oil emulsion separation. Downstream heat tracer
crude flows to the second separation stage into three-phase separator for degassing and
dehydration. Dehydrated crude with residual water cut =5 % mass then flows to inlet header of
existing export pumps.
Water from three-separators is discharged in buffer-degassers, then (for additional settling)
water runs to water treatment tank and then to water injection pump suction for further
injection in dedicated well.
Gas from first, second-stage separations flows to KO drum and then to flare. It is possible to
transport gas partly from the Asmari or Sarvak formations through an 8” pipeline to CPF.
Degassed and dehydrated Asmari crude is transported to CPF by export centrifugal pumps.
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
Start-up Complex IV
The following additional equipment would be required since start-up complex IV operation
start for Asmari and Sarvak crude separate treatment:
 New MPP for Asmari process line, (4-P-01 A/B), (4-MX-01 )
Asmari gas-saturated water/oil emulsion flows to oil/gas separators’ inlet for crude degassing.
Partially degassed oil flows to three-phase separators (second stage), where dissolved gas is
released and oil is dehydrated.
Gas from first and second separation stages flows to KO drum and then mixed with dehydrated
oil flow.
Dehydrated oil (residual water cut 5 % mass) downstream three-phase separators is mixed with
gas flow and comes to the inlet header of new export MPP.
Water from three-phase separators is discharged in buffer-degassers, then (for additional
settling) water comes to integrated water treatment system and then to water injection pumps’
suction for further injection in dedicated well.
Drains from pressure equipment, pipe gas expander and pump equipment are discharged in UG
drain tank with two semi-submersible pump units.
Sarvak partially degassed oil downstream existing oil/gas separators flows to line heater, where
it is heated to temperature required for better separation of water/oil emulsion. Downstream
the line heater oil flows to three-phase separators (second stage), where dissolved gas is released
and oil is dehydrated. Dehydrated oil (residual water cut 5 % mass) then comes to the inlet
header of export pumps.
West Paydar Sarvak gas after separation at new/existing separators in FWKOP is fed via
existing 8” flowline to Cheshmeh Khosh CPF.
6.4. Crude Transportation
West Paydar Asmari and Aban crude after produced water separation at FWKOP together with
associated gas is fed by Multi phase Pumps via existing 16” and 6”/8” pipe lines to Cheshmeh
Khosh CPF.
West Paydar Sarvak crude after produced water separation at new FWKOP is fed by centrifugal
pump via existing 10” flowline to Cheshmeh Khosh CPF.
Due volume of West Paydar Sarvak associated gas will be used for FWKOP auxiliaries, and excess
gas via existing 8” flowline is fed to Cheshmeh Khosh CPF.
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
6.5. Cheshmen-Khosh CPF
Main treatment (dehydration, degassing, desalination, etc.) of the Aban and West Paydar fluid is
provided at Cheshmeh Khosh CPF.
Cheshmeh Khosh CPF includes four process trains (BANKS A, B, C and D) and a desalter
package. Currently gas is flared. In addition to the above fields, the suction header of Cheshmeh
Khosh CPF also receives crude oil from the PAYDAR, DALPARI and Cheshme Khosh fields.
It is required to treat Aban and West Paydar field’s fluid at the separate Bank from other fields so
providing proper isolation system, maximum usage of existing equipment, high performance
metering and analysis are the main project objective at Cheshmeh Khosh CPF.
The following facilities required to be installed and modified:
6.6. Repair of Bank D
According to existing CPF process diagram, Bank D is used for combined treatment of well
products from different fields. To fulfill the requirements of project and to prevent possible
mixing of Asmari (West Paydar) products with products from other fields before metering, Bank
D, will be repaired. Repair works include isolation of Bank D from CPF distribution and gathering
manifolds with products of other fields, and elimination of crossflow between Bank D and other
Banks.
6.7. Upgrade of Test Line
It is planned to use existing test line to treat well products from Aban and West Paydar (Sarvak
formation) at Cheshmeh Khosh CPF. Due to little volume of existing test separator and lack of
accurate information about its technical condition, a new three-phase separator will be installed
for oil treatment at test line. Separated Gas, water and oil will be routed to the existing facilities.
Separated Sarvak sour oil from bottom of three—phase separator will be routed to existing Old
oil stripper tower for further sweetening by plant fuel gas.
6.8. Crude Oil Metering at CCTMU
After treatment of crude oil coming from West Paydar at Cheshmeh Khosh CPF, quality and
quantity of the Aban and West Paydar crude oil will be measured at CCTMU (downstream Tank-
E) that meets the requirements of project specification.
Title:
Process Description

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1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
6.9. Chemical and Analytical Laboratory
Chemical and analytical laboratory (CAL) is a separate industrial-type building, equipped with
required utilities: lighting, heating, plenum and exhaust ventilation, air conditioning, cold/hot
water supply, sewage, communication, security, emergency and fire-fight alarm.
Design laboratory is for lab tests for analytic quality control of raw materials coming to CPF:
− Produced oil, Stock tank oil;
− Associated gas;
− Injection water.
Quality laboratory test results are provided in accordance with technical design
assignment.
7. UTILITIES
Main Utilities and their characteristics which are required for this project are listed hereafter.
7.1 Fuel Gas
Source of fuel gas is from Gas Knock out Drums in West Paydar and Aban new
facilities (FWKOP) and in Cheshmeh Khosh CPF must be prepared from existing fuel
gas drum (if any).
7.2 Instrument air /Plant air
No instrument air and plant air consumption are foreseen in West Paydar and Aban FWKOP
since all control valves and shut down valves will be actuated by Electrical.
In Cheshmeh Khosh CPF, Instrument and Plant air is prepared by existing Instrument packages (if
any).
Operating and Design Conditions of Instrument & Plant air in Cheshmeh Khosh to be specified
by EPC contractor.
Title:
Process Description

Page 15 of 15
1063-FD-TR-00-00-PS-BD-0016 Rev.: 03
7.3 Flaring system
Flare system package shall be considered for collecting and burning of all the disposal gases.
Flare package includes flare K.O. drum, ignition system & flare stack in FWKOP and existing
flare package can be used in Cheshmeh Kosh CPF.
7.4 Burn Pit
New Burn Pit package shall be considered for collecting and burning of all the disposal liquids
inside West Paydar and Aban FWKOP.
New Burn Pit package includes Ignition system & Concrete pit in West Paydar and Aban
FWKOP.

1063 FD TR 00 00 PS BD 0016 03

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Aban & West Paydar Oil Field Development Project

(FEED, Detailed Design of Earthworks &

Document No.: Class: 3

03 27-Sep-20 Issued for Information H.Ghods H.Ebrahimi A. Zamani

Document No.: Class: 3

TABULATION OF REVISED PAGES

Document No.: Class: 3

Document No.: Class: 3

CLIENT/OWNER ZN-Vostok Ltd.

FEED Front End Engineering Design

2. PROJECT DESCRIPTION AND SCOPE OF WORK

Document No.: Class: 3

3. CODE AND STANDARDS

Process Flow Diagram West Paydar FWKOP 1063-FD-TR-00-00-PS-PF-0001

Process Flow Diagram Aban FWKOP 1063-FD-TR-00-00-PS-PF-0002

CPF: Central Processing Facilities

Each Aban and West Paydar oilfield includes the following:

Document No.: Class: 3

6.1. Wellhead Facilities

6.1.1. Aban Wells infrastructure

Two categories are considered for Aban wells:

6.1.2. West Paydar Wells infrastructure

Four categories are considered for West Paydar wells:

Document No.: Class: 3

 Power supply network

6.3. Free Water Knock Out Package (FWKOP)

Document No.: Class: 3

At Aban manifold, no water separation is performed.

Process Description of West Paydar field is as follows:

Document No.: Class: 3

Process Description of Aban field is as follows:

Flare system includes Flare Stack and Flare KO drum.

6.3.1. West Paydar FWKOP facilities commissioning levels

Document No.: Class: 3

 Three-phase separator, (4-PV-02 A/B)

 Existing oil and gas separators for Sarvak, (4-PV-03 A/B)

 Pipe gas expander (Flare K.O. Drum), (4-PV-08)

 Corrosion inhibitor Package (4-CIU-02)

 Three-phase separator, (4-PV-02 C/D)

Document No.: Class: 3

 Heater with intermediate heat carrier for Asmari line,(4-HT-02 A/B/C)

Start-up Complex III

Document No.: Class: 3

6.4. Crude Transportation

Document No.: Class: 3

6.5. Cheshmen-Khosh CPF

6.6. Repair of Bank D

6.7. Upgrade of Test Line

6.8. Crude Oil Metering at CCTMU

Document No.: Class: 3

6.9. Chemical and Analytical Laboratory

7.1 Fuel Gas

7.2 Instrument air /Plant air

Document No.: Class: 3

7.3 Flaring system

7.4 Burn Pit

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