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PHM-120-FF-004
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Date
: 27 Aug 04
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27 Aug 04
VWY
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16 Aug 04
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24 May 04
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5 May 04
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REV
DATE
DESCRIPTION
PREP'D
CHKD
APP'D
CLIENT
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Document No
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TABLE OF CONTENTS
1
INTRODUCTION
1.1
Project Introduction
1.2
Objective
1.3
MANNING OVERVIEW
2.1
Wellsites
2.2
Main Pipeline
2.3
3.1
Wellsite Control
3.2
GPP Control
4.1
Introduction
4.2
10
4.3
10
4.4
11
4.5
12
13
5.1
Introduction
13
5.2
13
5.3
14
5.4
Slug Control
15
5.5
16
REFERENCES
18
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IN T R O D U C T IO N
1.1
Project Introduction
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Amerada Hess Thailand Ltd (AHT), plan to develop the Phu Horm gas reserves for export
to Nam Phong Power Plant near Khon Kaen. The Phu Horm gas field is located in Phu
Horm, Udorn Thani Province in Northern Thailand about 30 km south of Udon Thani and 90
km north of Khon Kaen.
The gas field is in a forested National Park and is in an ecologically and environmentally
sensitive area. All development activities must take cognisance of this and will need to be
undertaken in close co-operation with the relevant local and regional authorities as well as
stakeholders and the local population.
The expected production rate will average 135 MMSCFD with an expected field life of
approximately 20+ years.
Reservoir fluids will be initially gathered at 3 well sites PH-3, PH-4 and PH-5, each with
provision for five (5) wells. Production from the wells on PH-3 will be manifolded together
and exported directly to PH-5. Fluid production from the wells on PH-4 will be manifolded
together and exported directly to PH-5.
PH-5 will have a common manifold to receive the liquids from PH-3, PH-4 and PH-5. The
fluids received at the PH-5 common manifold will be transported via pipeline (free-flow) to a
new stand-alone Gas Processing Plant (GPP) in the Nam Phong area close to the existing
ExxonMobil and Petroleum Authority of Thailand (PTT) gas processing plants. The pipeline
will be a wet multiphase pipeline, approximately 60 km long and is expected to be between
16 to 20 diameter.
Reservoir fluids will be received at the new AHT Gas Processing Plant where liquids will be
separated. The saturated gas will be dehydrated, metered and transported onward to the
Electricity Generating Authority of Thailand (EGAT) Nam Phong Power Plant via a tie-in to
the PTT plant metering system.
The condensate produced will be stabilized and stored for export via road tankers. The
produced water will be treated for disposal.
1.2
Objective
The purpose of this philosophy is to define overall operating and control strategies for the
Phu Horm facilities.
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1.3
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AHT
CR
Control Room
CCR
CCTV
DCSS
EGAT
ESD
Emergency Shutdown
FGS
FO
Fibre Optics
GPP
HIPPS
IER
JT
Joule-Thomson
LP
Low Pressure
LTS
MCC
MAOP
OIS
PCS
PSD
Process Shutdown
PTT
RTU
SDS
Shutdown System
SDV
Shutdown Valve
WHSC
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M A NN I NG OV ER VI EW
The operating philosophy for the facilities must be aligned with a manning philosophy. The
general manning philosophy for the Phu Horm production system is summarised in the
following sections.
2.1
Wellsites
From an Operations perspective, the wellsites will be minimally manned.
Each individual wellsite will have a single security guard present on 24 hour basis. The
primary role of the security guard is to ensure the facilities are protected against theft or
vandalism. The security guard will not operate the facilities, but would have the following
limited operational roles;
The security guard will have the appropriate training and authority to initiate a Level
3 PSD or Level 4 ESD using local pushbuttons if required.
The security guard can provide emergency assistance to the day operator as
required.
A day operator will provide operations support for the three wellsites. The day operator will
visit each wellsite on a daily basis to;
Replace consumables (fuel, chemicals) and drain any accumulated liquids from the
process where appropriate.
Each wellsite will be provided with CCTV coverage, relayed back to the GPP CCR by the
telecommunications system.
A small operations/supply depot would be established at the existing base camp near
PH-1. The depot would be used for storage of wellsite consumables and it is assumed the
day operator would reside nearby. This would allow the day operator to be on call and able
to reach both the depot and the wellsites relatively quickly if required.
2.2
Main Pipeline
Block valve stations are provided along the main pipeline with no manning. However, there
will be routine inspection by an operation crew from the GPP and any manual intervention
required can be performed during these visits.
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The operating conditions (pressure, temperature) and valve status at each block valve
station will be transmitted to the GPP and visible to the GPP CCR operator.
2.3
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C O N T R O L S YS T EM OV ER VI EW
The process control philosophy for the facilities must be aligned with the proposed control
system. A brief summary of the Phu Horm control system is provided in the following
sections.
3.1
Wellsite Control
The wellsites are provided with Remote Telemetry Units (RTU) for control, monitoring and
safety purposes. The RTU is an intelligent and stand-alone unit, which can perform simple
control logic. Data from each of the RTU is transmitted to the GPP using Fibre Optics (FO)
for computation. Based on the computation results, an appropriate control set point based
on pressure or flow is passed back to the RTU from the GPP.
The RTU accepts either a flow or pressure set point for each choke from the GPP control
room and modulates each stepping choke valve as required. On loss of signal
(communications failure) the RTU will continue to control at the last received set point.
However, a choke under flow control will switch to pressure control if the pressure reaches
a pre-set pressure limit.
Each of the wellsites is provided with a single Wellhead Safety Cabinet (WHSC) for standalone control and safety protection of wellhead operation. Wellhead status is wired to the
RTU and transmitted to the GPP.
The choke position on each wellhead is controlled by the RTU to meet flow or pressure set
points. Chokes are hydraulically actuated, the hydraulic fluid supplied by the WHSC
hydraulic system.
The wellhead heaters (if required) and other packaged equipment are controlled via standalone local control panels, which control the unit operation based on preset set points.
Where local control panels are installed, they are provided with manual start/stop operation
for operator intervention.
The RTU monitors the status of packaged equipment and relays information back to the
GPP. The RTU is not provided with Operator Interface Station (OIS). However, it can be
connected to a laptop computer when required.
3.2
GPP Control
Process control, monitoring and safety shutdown in the GPP is performed by the Process
Control and Safety System (PCSS). The PCSS consists of the Process Control System
(PCS), the Shutdown System (SDS) and the Fire & Gas System (FGS) integrated into a
complete system sharing a common database.
The PCSS is also capable of limited remote control, monitoring and shutdown of the well
sites and sectioning valve stations as follows:
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Receiving computed wellhead flow signals from wet gas metering for computation
of the total wells production against supply to the power plant.
Transmitting control set points based on pressure or flow to the RTU for local
control of hydraulic actuated choke valve to meet demand.
Initiating closure of block valves at the pipeline valve stations (signal on to initiate
shutdown). However, the block valves cannot be re-opened remotely.
A Central Control Room (CCR) is provided at GPP for housing all electronic equipment,
instrumentation and computers. The CCR consists of the Control Room (CR) and the
Instrument Equipment Room (IER).
Equipment requiring operator intervention is housed in the Control Room. This includes but
is not limited to workstations, console switches and pushbuttons, data acquisition systems
and CCTV.
Other equipment that does not require operator intervention is housed in the IER such as
the interface and system cabinets, telecommunication equipment and flow computers.
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SY ST E M C O N T R O L OV ER VI EW
4.1
Introduction
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The overall objective of the Phu Horm process system is to deliver gas to PTT that meets
contractual specifications on pressure, temperature and quality. As the specifications are
defined at export, the following sections describe the control system, starting from the
export system and working back up the supply train.
It should be noted that currently there is no formal contractual arrangement between AHT
and PTT. This creates a number of uncertainties for the control system. In particular;
The range of sales gas delivery pressures is not defined. For design purposes the
maximum backpressure in the supply line to PTT is taken as 27.6 barg (400 psig)
[1]. However, the minimum and normal supply pressure to PTT is not known.
It is not known whether the gas transfer between AHT and PTT will be demand
driven (pressure control) or flow nominated (flow rate control).
The size and rate of gas demand swings are not formally defined [1].
As such, the control system has been defined to be robust as practical against these
uncertainties.
The overall control scheme is summarised in Figure 4.1. The key features of the control
scheme are discussed in the following sections.
Figure 4.1 - Control System Overview
Wellpad B
and C
Wellpad A (Typical)
Supervisory
Control
Override
TC
PC
PC
>
>
FC
FC
PC Other Wells
PC
TC
Inlet Heater
Inlet PCV
Glycol
Dehydration
LC
Slug Catcher
LC
Level override
during pigging
To condensate
stabilisation
To produced
water system
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4.2
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MODE A: If sales are nomination based, PTT would nominate a target flow rate to
be delivered over a defined period to meet expected demand from downstream
consumers. In this scenario the final control valves would be configured for flow
control. This mode of operation would allow export pipeline pressure to float.
With two suppliers (AHT and ExxonMobil) PTT may choose to place one party on flow
control and the second party on pressure control. Typically, the larger contributor (AHT)
would be the swing producer on pressure control, however at this point in time sales
arrangements are not defined. As such, the Phu Horm system has been designed to
operate in either mode.
In both scenarios the control valves downstream of metering can act to segregate GPP
operation from fluctuations in PTT pressure. This ensures the operating pressure in the gas
dehydration system remains within a stable operating range and does not float at a variable
PTT backpressure.
It should be noted that, as the Phu Horm production system is fed by a multiphase pipeline,
it will be subject to limitations as to how rapidly the system can respond to large demand
changes. Although the system should be able to accept small rate changes without
restriction, larger rate changes will need to be made at a controlled rate to manage the
liquid inventory in the pipeline system.
It is essential that potential limitations in operating flexibility be quantified and allowed for
when committing to contractual obligations with downstream customers.
For design purposes, the control system will be configured to be able to operate in either
demand driven or rate nominated mode. A supervisory control system will be required to
override demand control, if the rate or magnitude of flow change is outside the flow or
pressure operating envelope of the Phu Horm production system.
4.3
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Ensuring inlet temperatures to the gas dehydration system are greater than 10C.
If temperatures fall below target temperatures of either 20C for the sales gas, or 15C for
the inlet gas, associated temperature controllers will regulate the inlet heater to
compensate.
In general the sales gas temperature is expected to be normally controlling, but the inlet
gas temperature may become controlling under transient conditions. Monitoring the inlet
gas temperature in this way also acts as a feed-forward controller to help maintain sales
gas temperature.
4.4
Two sets of pressure control valve, installed in parallel, have been proposed.
They will be configured on two independent pressure controllers in order to
eliminate common mode failure.
The pressure set points will be staggered (33 and 32 barg). This staggering will
help ensuring that only one control valve (with higher set point 33 barg) will be
operational during high upstream pressure. This scenario will force other control
valve to be closed. However, during normal (unpacked) operation, both the control
valve will stay open.
They will be designed in split range of total flow conditions. The proposed
maximum flow conditions for each valve are as follows:
Maximum Flow Conditions
Normal Operation
Packed operation
Flow
(MMscfd)
70
135
Inlet Pressure
(barg)
35
65
Outlet Pressure
(barg)
32
33
The slugcatcher has an additional pressure control valve that allows flow to the flare during
pigging operations. The sizing of this pressure control valve should be verified by dynamic
modelling of the pipeline under pigging conditions.
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In detailed design consideration can be given to leaving this valve operational at all times
with an elevated setpoint in order to actively prevent pipeline packing. .
4.5
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PI PE L IN E S YS T EM OP ER A T ION
5.1
Introduction
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Gathering pipelines linking Wellsites PH-3 and PH-4 to Wellsite PH-5. The
gathering pipelines are anticipated to be 10 in diameter.
Main pipeline linking Wellsite PH-5 to the Gas Processing Plant. This pipeline is
anticipated to be 18 in diameter.
All the pipelines are wet, multiphase pipelines. In addition to the gas flow, the pipelines will
transport approximately 5 bbl/MMscf of condensate and up to 5.6 bbl/MMscf of free water.
The Maximum Allowable Operating Pressure (MAOP) for the pipelines will be based on
600# piping class and will be 94.4 barg. Overpressure protection for the gathering pipelines
and main pipeline will be by a High Integrity Pressure Protection System (HIPPS) installed
at each wellsite.
5.2
Packing the pipeline requires more pressure drop to be taken across the inlet
pressure control valves at GPP. Under winter inlet conditions the temperatures to
the GPP glycol contactor would fall as low as 10C. These cold inlet temperatures
are too low for the glycol dehydration system, which requires a minimum
temperature of 10C. The cold temperatures are also inside the hydrate formation
region.
Packed operation lowers gas velocities in the pipeline system and increases liquid
holdup. The greater liquid holdup increases the risk of pipeline slugging and
reduces pipeline operating flexibility.
Packed operation imposes higher overpressure protection relief rates on GPP for
the inlet control valve failure scenario.
As a result, the default operating mode for the pipeline system will be unpacked operation.
This mode of operation;
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Lowers the average operating pressure in the pipeline, increasing gas velocity,
reducing liquid hold-up and improving operating flexibility.
In unpacked operation, the pipeline system is controlled by adjusting well rates to maintain
a target pressure in the slug catcher. The pressure does not have to be controlled precisely
but would typically float in a band of 5 bar, with the control valves on the slug catcher gas
outlet ensuring a stable GPP inlet pressure.
With the main pipeline outlet pressure operating in this band, the main variation in pipeline
pressure will be seen at the inlet to the pipeline, with the inlet pressure floating as a
function of flow and pressure drop through the pipeline system.
Although the default operating mode is for unpacked operation, the system can be
operated in a packed condition, if operating conditions are favourable and the capacity of
the downstream relief system is sufficient. For example, when capacity is available it is
expected that the operators would tend to operate the slugcatcher at a 43 barg rather than
the minimum of 36 barg in order to provide some flexibility. This minor packing has been
taken into consideration in liquid management studies, and is different to major packing
which would involve operating the pipeline inlet at say 90 barg and the slugcatcher at 75
barg.
Because packed operation imposes a large potential gas blow-by relief case on GPP, the
GPP slugcatcher will have a high pressure trip set at 70 barg. This is above the normal
pipeline settle-out pressure and will allow some pipeline packing. However, operation or
settle-out pressure higher than 70 barg at GPP will trigger a Level 3 PSD and will require
pressures to be reduced before restart.
5.3
Production rate. The liquid inventory increases under turndown as gas velocities
reduce and liquid levels in the pipeline system rise.
Liquid load. The liquid inventory is related to the quantity of liquid input into the
pipeline. Thus free water breakthrough will increase the liquid holdup in the
pipeline system.
Management of the liquid inventory in the pipeline system will be based on the following
operating philosophy;
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While the optimum combination of slug catcher size and excess liquid processing capacity
must be identified by pipeline system dynamic studies, the underlying operating philosophy
is defined as follows;
The ramp-up slug is defined by ramping up production from a turndown case. The
rate of ramp-up may be defined by contractual obligations to downstream
customers.
The production ramp-up will displace accumulated liquid inventory from the
pipeline. This liquid will arrive at GPP at a rate that will exceed the steady state
liquid rate.
5.4
Slug catcher capacity that provides liquid storage volume for the transient
liquids to be stored until they can be processed.
Slug Control
In addition to the measures already discussed above in 5.3, a level control valve has been
installed upstream of the slug catcher. The operation of the control valve is based on the
following premises:
During normal operation, the control valve will be bypassed. The control valve will
be active only during pigging operation.
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During pigging, the liquid arrival rate will exceed the capacity of the slugcatcher
and the downstream processing systems. Under these conditions the level control
valve upstream of the slugcatcher will restrict the incoming flow. The requirement
to restrict flow may come from either the interface level controller or the
condensate level controller.
The control valve is proposed to be a V-port type due to the high pressure drop
across control valve, no requirement for fine control and requirement for quick
action.
The sizing of the slug control valve should be verified by dynamic modelling of the pipeline
under pigging conditions.
5.5
5.5.1
Condensate Processing
The condensate will be drawn from the slug catcher via a level control valve. Liquid flows
will vary over a wide operating range, with normal steady state rates of 5 m/h, but peak
rates during ramp-up of 80m/h. Two control valves in parallel have been proposed to cover
entire range of flows and pressures.
The condensate will be flash stabilised in the Condensate Flash Vessel, with condensate
heaters installed to add heat under winter operating conditions. Give the wide operating
range two 50% heaters are proposed, with production normally routed through one heater
to limit turndown. Both heaters are provided for large ramp-ups under winter conditions.
However, as these are planned events, it is proposed the second heater is brought on-line
manually as required.
Flash gas from the condensate flash vessel is routed to the LP flare. Pressure in the
condensate flash vessel is set at 3 barg, sufficient to drive condensate through to the
condensate storage tank and water through to the CPI vessel. Nitrogen blanketing is used
to maintain vessel pressure if there is insufficient flash gas.
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5.5.2
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R EF E R EN C ES
1. Amerada Hess Facilities Basis Of Design, Rev 2, 17 Mar 04
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