OFON EXPORT PUMP POWER

INVESTIGATION
OML102 October 2021
23th

© Laurent Pascal/Total
 OFON OIL SYSTEM REVIEW: PURPOSE & SCOPE
Objective of this document is to review Ofon process system and highlight the key differences of the current operating mode with
the original process design and assess impact of increasing BSW on the equipment and overall process. Key equipment assessed
are the following:
a. MP Separator e. Oil Booster Pumps
b. Crude Pre-heater f. Export Cooler
c. Inter-stage Heater g. Oil Export Pumps
d. LP Separator h. Export Metering
Equipment Design Case Current Case Conclusion
MP Designed to operate in three phase Currently operated in two phase mode with MP Separator Operating
Separator mode with weir plate. For Scenario weir plate removed (PWRI not operational). with design limit. No impact
(28 VS 2020) 1 design basis, it can handle up to Current operating P&T in line with design. due to increasing BSW.
100kbwpd corresponding to 74% BSW falls within 25-30% with a total liquid
BSW. production of 65-70 kblpd.
Crude Pre- Pre-heats the HC liquid from MP Crude pre-heaters are currently by-passed No impact due to
Heaters Separator to reduce HW since the objective of the pre-heaters is to increasing BSW.
(28ES 2023 requirement on the Interstate serve as economizer for the inter-stage
A/B) heater. heaters to improve oil/water separation.
Inter-Stage Heats the incoming crude to 55 oC to Inter-stage heaters (currently not in use) to No impact due to
Heaters improve separation, achieve RVP be used for improved separation, achieve increasing BSW impact.
(28 ES 2024 and reduce demulsifier RVP and reduction in demulsifier Inter-stage heaters to be
A/B) consumption. consumption. lined up once the PWRI
becomes operational to
improve of emulsion &
demulsifier cost.
LP Separator Designed to operate in three phase The LP separator is operated in two phase No impact due to
(28 VS 2040) mode with weir plate. For scenario 2 mode. BSW falls within 25-30% with a total increasing BSW.
design basis, it can handle up to liquid production of 65-70 kblpd. LP Separator is very well
115 kbwpd corresponding to 75% within the design range.
BSW.

Ofon Phase 2 Export Pump Power Investigation

 OFON PROCESS SYSTEM REVIEW
Equipment Design Conderation
Oil booster Design flow rate specified
pumps by operating manual is
(28 PA 2501 283 m3/hr (42.5 Kblpd).
A/B/C) Allowable Operating point
is 288 barg on the pump
curve.
Oil export The maximum operating
cooler temperature is limited to
(28 ES 2526) 60°C due to external
coating thermal
resistance, bottom riser
expansion and cathodic
protection efficiency.
Current Case Conclusion
flow rate through the pumps was reduced from Recommendation to reduce pump
288 m3/h to 250 m3/h to accommodate flowrate through the pump to 200 m3/hr
increased BSW. Recommendation is to reduce which will further reduce pump recycle
rate further to 200 m3/h accommodate
increasing BSW.
Not currently in use to reduce oil temperature to No impact due to increasing BSW.
below 55°C to avoid putting additional demand Detailed vibrational study is required to
on CW system compared to the current load. confirm the source of vibrations around
CW system flowrate is reduced by running only the valve..
one sea water lift pump due to severe vibration
observed on the seawater overboard PV at
flowrates over 4000m3/h.
On the other hand, demand for CW will likely be
reduced over time due to reduced produced gas
rate

Oil export Design BEP flowrate is Oil export pumps: current flow rate is at 380 Currently not impacted by increasing
pumps 400m3/hr. Preferred m3/h below the tested flow rates for OEP A and BSW due to margin on pump design
(28 PA 2505 Operating Range: 308 to OEP B which is 450m3/hr@13% BSW and capacity vs current rate. With increasing
A/B/C) 527m3/hr) 490m3/hr respectively. Today we are at 1445 KW BSW and motor power approaching
Rated Power: 1475KW (zero recycle). Oil export LV 204001 A/B rated capacity, there will be need to run
vibrations at high delta pressure (around 100 two pumps in the future. Further BSW
barg) were observed in the past (current increase and flowrate will necessitate
operating DP is around 70 barg). running the two pumps. LV Replacement
is planned
Oil metering 3x50% design Oil export flowrate is <390m3/hr. Current BSW is Online analyzer BSW capacity already
unit configuration. Design outside of the online analyzer design range (0- exceeded (0-10%) and autosampler
(28 UN 2601) flowrate is 727m3/hr. 10%). Calculation using densitometer was working range (<20%). BSW calculation
Operating Rate is 48 to introduced to compensate lack of online is done by manual sampling
727. analyzer. Autosampler and manual sampling are densitometer 28-AT-260202.
available.

Ofon Oil Process Review

 OFON PHASE 2 OIL SEPARATION & EXPORT SYSTEM

Ofon Phase 2 Export Pump Power Investigation

 OFON PHASE 2 COMPRESSION & DEHYDRATION SYSTEM

Ofon Phase 2 Export Pump Power Investigation

 OFON PRODUCTION FORCAST
OFON PHASE 2, 18 YEAR PRODUCTION FORCAST
80000 3.00

70000
2.50

60000

2.00
Oil, Wter,LiquiD, blpd

50000

Gas, mmpd
40000 1.50

30000
1.00

20000

0.50
10000

0 0.00
2020 2022 2024 2026 2028 2030 2032 2034 2036 2038 2040

Production Yr

Oil Water Total Liquid Gas

Ofon Phase 2 Export Pump Power Investigation

 PEAK PRODUCTION FORCAST VALUES PER DAY BASIS
PEAK OIL RATES  Remarks

YEAR OIL WATER GAS TOTAL LIQUID

Bopd Bwpd Mm3pd Bpd

2020 45,941.22 14,490.85 0.14 60,432.07

PEAK WATER
 

2030 19,723.87 37,509.96 1.71 57,233.83

PEAK LIQUID

2023 38593.07 30760.42 2.37 69353.49

PEAK GAS  

2025 30,135.1 33,732.17 2.42 63,867.27

Ofon Phase 2 Export Pump Power Investigation

 OFON PHASE 2 OIL EXPORT CAPACITY CHECK
BASIS: INCREASE IN WATERCUT

Ofon Phase 2 Export Pump Power Investigation

 OFON PHASE 2 UNITS CAPACITY CHECKS SUMMARY

`   SEPARATORS
    Medium Pressure (MP)   Low Pressure(LP)
   
Design Current Sensitivity Design Current Sensitivity Remarks
   
    YR 2013 YR 2021 YR 2023 YR 2025 YR 2030 YR 2012 YR 2021 YR 2023 YR 2025 YR 2030  
        Peak Liq Peak Gas Peak Water     Peak Liq Peak Gas Peak Water  
Operating Temperature o
C 65 42.5 42.5 42.5 42.5 41 42.5 77 42.5 73  
Operating Pressure barg 13.5 5.6 5.6 5.6 5.6 2.5 1.4 .1.4 1.4 1.4  
  Flow & Properties
Gas Flow Am3/h 24835 16535.7 16570 16738.85 11854.49 6800 425.68 766.41 660.34 426.23 `
Oil Flow Am3/h 714 279.02 230.21 199.675 130.7 770 260.67 206.49 181.36 118.23  
Water m /h3
259 126.50 203.00 223.51 248.5 22 126.44 203.75 223.5 248.54  
Oil Density kg/m3 804 766.6 781.95 766.59 760 803 775.56 747.13 747.72 748.01  
Water Density kg/m 3
988 991.5 999.01 991.5 991.5 980 991.41 973.72 973.72 973.72  
Two Phase Flow m3/h - 843.8 893.23 892.74 369.179 - 381.11 410.22 404.85 366.77  
HEATING EQUIPMENTS
Crrude Oil Pre- Heater (28ES2023A/B)   Remarks Interstage Heater(28ES2024A/B)  
Operating Temperature In,
Shell Side o
C 41 42.5 42.5 42.5   170 170 170  
Operating Temperature Out ,
Shell Side o
C 51 51 51 51   126 126 126  
Operating Temperature In , No Heating

No Heating
Tube Side o
C 77 77.28 77.27 66   51 51 51  
Operating Temperature Out ,
Tube Side o
C 58 68.28 68.86 57   77 77 77  
Duty, Specified kw 2635 2635 2635 2635   7340 7340 7340  
Duty, Calculated kw - 331 342 344 OK 1049 1081 1052 OK
Area, Specified m 2
698 698 698 698   261 261 261  
Area, Calculated m2 - 200 201 303 OK 227 239 246 OK
    ROTATING EQUIPMENTS
  Booster Pumps(28PA2501A/B/C) Remarks Export Pumps(28PA2505A/B/C)
Operating Pressure, Suction barg 2.4 1.4 1.4 1.4 2.4   7 4 4 4  
Operating Pressure, Dischrge barg 6.1 7 7.7 7.2 7.8   102 100 102 108  
Operating Mode % 2X50% 2X50% 2x50% 2x50% 2x50%   1X100% 1X100% 1X100% 1X100%  
Flow, Rated m3/h 282 282 282 282 282   400 400 400 400  
Flow,Calculated m /h3
- 201 228 202 189   387 400 400 366  
Power kw 90 65.6 74.5 70.8 68.38 OK 1300 1372 1391 1369 OK
  COOLING EQUIPMENT
  EXPORT COOLER (28ES2526A/B)
Operating Temperature In,
Shell Side o
C 34 34 34 34    
Export Cooler Not in Use

Operating Temperature Out ,

Shell Side o
C 50 50 50 50    
Operating Temperature In ,
Tube Side o
C 80.3 77 77 77    
Operating Temperature Out ,
Tube Side o
C 55 55 55 55    
Duty specified kw 3370 3370 3370 3370    
Duty calculated kw - 1079 1122 1080 OK  
Area Specified m 2
537 537 537 537    
Area calculated m 2
- 490 504 479 OK

Ofon Phase 2 Export Pump Power Investigation

 OFON PHASE 2 OIL EXPORT CAPACITY CHECK
BASIS:MP SEPARATOR NOZZLES CHECK

      SEPARATOR

    Medium Pressure (MP)

   
Current Sensitivity Remarks
   
YR 2021 YR 2023 YR 2025 YR 2030  
     
Size Peak Liq Peak Gas Peak Water  
Parameters  
         
Nozzle Inch Criteria
       

Gas Flow (kg/h) 80931.871 83416.116 84640.26 59777.56  

   
Liquid Flow (kg/h) 335,427.89 371,353.89 37,082.78 343,846.25  

ev2 1340 1524 1548 980 OK

Inlet 36
ev2,max 2000 2000 2000 2000  

Vel 0.758 0.806 0.794 0.715 OK

Liquid Outlet 18
Vel, max 1.5 1.5 1.5 1.5  

ᵨv2 659 704 725 364 OK

Gas Outlet 28
ᵨv2,max 3750 3750 3750 3750  

Feasibility Study of Fuel Gas Emission Reduction Project

 OFON PHASE 2 OIL EXPORT CAPACITY CHECK
BASIS: LP SEPARATOR NOZZLES CHECK

      SEPARATOR

    Low Pressure (MP)

   
Current Sensitivity Remarks

   
YR 2021 YR 2023 YR 2025 YR 2030  
     
Size   Peak Liq Peak Gas Peak Water  
Parameters  
         
Nozzle Inch Criteria
         

Gas Flow     3,004.51 2,291.18 1,959.25 1,258.43  

Liquid Flow     331,082.16 367,972.38 367,844.20 342,587.87  

400 277 OK
ev2 464 441
Inlet 24
ev2,max 2000 2000 2000 2000  
0.61 0.55 OK
Vel 0.583 0.62
Liquid Outlet 20
Vel, max 1.5 1.5 1.5 1.5  
43 25 OK
ᵨv2 19 8
Gas Outlet 12
ᵨv2,max 3750 3750 3750 3750  

Feasibility Study of Fuel Gas Emission Reduction Project

 CONCLUSION

● For the cases considered, the following summary are drawn

● MP LP separators nozzles:
● Inlet, Gas outlet, Liquid Outlet all meant the momentum and velocity
criteria, whence no issues
● Booster pumps can perform both zero and partial recycle and meet
the power requirement for the worst case scenario of maximum
BSW% of 65.63%
● Analysis shown that the current mode operation mode of 1x
100%,for the export pump is adequate, as increase in BSW% does
not have much impact in terms of power consumption by each of the
pump.
● For the current year 2021, with heating and cooling by pass, the
temperature of crude to the export pump is below 55 degree Celsius.

Ofon Phase 2 Export Pump Power Investigation

 COMPRESSION SYSTEMS UNITS CHECKS

● The following gas compression units and dehydration units are

analysed
1. LP Compressor Suction Cooler-(28ES3111)
2. LP Compressor Suction Scrubber-(28VS3110)
3. LP Compressor Condensate Pump
4. LP Compressor unit A/B
5. MP Compressor Suction Cooler
6. MP Compressor Suction Scrubber
7. MP Compressor Unit
8. MP Compressor Discharge Cooler
9. Hp Compressor Suction Scrubber
10. HP Compressor Unit
11. HP 1st Stage Discharge Cooler-
12. HP 2nd Stage Discharge Cooler-
13. HP 3rd Stage discharge Cooler-

Feasibility Study of Fuel Gas Emission Reduction Project

 GAS COMPRESSION ANALYSIS RESULTS

Feasibility Study of Fuel Gas Emission Reduction Project

 CONCLUSION

Feasibility Study of Fuel Gas Emission Reduction Project

 GAS DEHYDRATION SYSTEM

● The following units were considered for the analysis

● 1. Dehydration scrubber-(28VS3141)
● 2. 28 VF 3149
● 3. TEG Contactor
● 4. 28UG 300

Feasibility Study of Fuel Gas Emission Reduction Project

 GAS DEHYDRATION SIMULATION PFD

Feasibility Study of Fuel Gas Emission Reduction Project

 DEHYDRATION RESULTS ANALYSIS

Feasibility Study of Fuel Gas Emission Reduction Project