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NAE DEEP OFFSHORE PROJECT



ETAN FPSO



EQUIPMENT SIZING / VALIDATION REPORT





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NAE DEEP OFFSHORE
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BW OFFSHORE INTERNATIONAL ENERGY SERVICES LTD.
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REVISION LIST







HOLD RECORD

















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TABLE OF CONTENTS

LIST OF TABLES ........................................................................................................................................... 5
LIST OF APPENDICES .................................................................................................................................. 5
LIST OF ABBREVIATIONS ........................................................................................................................... 6
1.0 INTRODUCTION .................................................................................................................................. 7
1.1 PROJECT OVERVIEW ........................................................................................................................ 7
2.0 OBJECTIVES ...................................................................................................................................... 8
3.0 PUMP SIZING ...................................................................................................................................... 9
3.1 PUMP SIZING CRITERIA .................................................................................................................... 9
3.2 FLUID PROPERTIES ........................................................................................................................ 10
3.3 ASSUMPTIONS ................................................................................................................................ 11
3.3.1 PRODUCED WATER TRANSFER PUMP ......................................................................................... 11
3.3.2 WATER INJECTION BOOSTER PUMPS .......................................................................................... 11
3.3.3 WATER INJECTION PUMPS ............................................................................................................ 11
3.4 CALCULATION PROCEDURE .......................................................................................................... 12
4.0 RESULTS / EVALUATION ................................................................................................................ 13
5.0 CONCLUSION ................................................................................................................................... 14
6.0 REFERENCES: ................................................................................................................................. 15
APPENDICES .............................................................................................................................................. 16



























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LIST OF TABLES
Table 1 Equipment Index
Table 2 Liquid line sizing for pump suction & discharge
Table 3 Fluid Properties
Table 4 Summary of Results






LIST OF APPENDICES
Appendix I Produced water pump sizing calculation
Appendix II Water Injection Pumps Sizing Calculation
Appendix III Heat & Material Balance For Maximum Oil & Gas (Start-up)
Appendix IV Heat & Material Balance For Maximum Water Case




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LIST OF ABBREVIATIONS




















































Abbreviations Meaning
bara Bar absolute
barg Bar guage
bpd Barrels per day
FEED Front End Engineering Design
FPSO Floating, Production, Storage & Offloading
HMB Heat & Material Balance
hp Horse power
IESL International Energy Services Limited
Kg/m3 Kilogram per cubic metre
kW kiloWatts
NAE Nigerian Agip Exploration Ltd
NPSHA Net Positive Suction Head Available
NPSHR Net Positive Suction Head Required
P&ID Piping & Instrumentation Diagram
psi Pound per square inch
SNEPCo Shell Nigeria Exploration & Production Company


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1.0 INTRODUCTION
1.1 Project Overview
Nigerian Agip Exploration Limited (NAE) and Shell Nigeria Exploration and Production Company
(SNEPCo) are in the process of developing NAE Deep Offshore Block located approximately
150kilometers offshore Nigeria. In particular, the block is a 1,958 km
2
block license located in the
deepwater eastern portion of the Niger Delta in Nigeria, with water depths ranging from 1,200 to 2,400
m.
The current development scenario involves production from subsea wells located in water depths
around 1,750 - 1800 meters. The wells would be conveyed to a moored ship-shaped FPSO. The
FPSO would be utilised for:
a. Stabilisation, dehydration, storage and export of crude oil product,
b. Dehydration, compression and export of gas,
c. Separation and treatment of produced water,
d. Seawater treatment;
e. Produced water and Seawater injection for Reservoir pressure maintenance
f. Power generation for FPSO marine, accommodation and process loads,
g. Gas lift at riser base at an appropriate pressure

The block (Fig. 1) comprises two discoveries, Zabazaba and Etan, which are separated by a significant
seafloor canyon. The field is in about 1,950 m water depth and the distance between Zabazaba and
Etan is about 30/40 km.

Figure 1: Block Location





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BW Offshore has therefore employed the services of IESL to carry out the Front End Engineering Design
(FEED) for the new Water injection and Produced Water Treatment modules/systems.
This document shows the process equipment sizing calculations carried out on the Produced Water
Treatment and New Water Injection modules.
2.0 OBJECTIVES
The purpose of this document is to provide the sizing calculations for the both the Produced Water and
Water Injection Pumps.

Table 1: Equipment Index
No. Description Tag Quantity P&ID Number(s)
1 Produced Water Transfer Pump
44PA101A/B/C
(3x50%)
3 4295-IES-P-XB-44005.001
2 Water Injection Booster Pumps
29PA101
A/B/C (3x50%)
3 4295-IES-P-XB-29004.001
3 Water Injection Pump 29PA102 A / B 2

4295-IES-P-XB-29005.001































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3.0 PUMP SIZING
3.1 Pump Sizing Criteria

The Water injection and injection booster pumps were sized in accordance with API RP 14E (Ref 8)
and the Eni exploration & production design criteria reference document for process minimum
requirement (Ref 9).
The following criteria form the basis for the pump sizing as per API 14E (Ref 8):
Velocity in the suction pipe shall be between 2 - 3 ft/s (Table 2.3).
Velocity in the discharge pipe shall be between 6 9 ft/s (Table 2.3).
Pump should be sized to provide adequate head required and to ensure that the NPSHA exceeds
the NPSHR (Ref 8) so that essentially no vapor will be flashed from the liquid as it enters the pump
casing or cylinder.
Similarly, Table 2 below shows the design criteria as specified in the Eni exploration & production
design criteria.
Table 2: Liquid line sizing for pump suction & discharge

SERVICE
P(bar) / 100m
Maximum
Velocity
(m/s)
Normal (Note 1) Maximum (Note 1)
Pump Suction
Liquid @ bubble point or with dissolved
gas ( 4)
Liquid at bubble point or with dissolved
gas ( 4-8)
Liquid at bubble point or with dissolved
gas ( 8)
Sub-cooled Liquid ( < 8)
Sub-cooled Liquid ( 8)

0.05

0.07


0.07




0.25


0.25

0.8



0.1


0.11




0.35


0.35

1.0



1.5


1.8




2.0


3.0





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Table 2: Liquid line sizing for pump suction & discharge (Contd)

SERVICE
P(bar) / 100m
Maximum
Velocity
(m/s)
Normal (Note 1) Maximum (Note 1)
Pump Discharge
Lines ( < 4)

Lines ( 8)


0.05

0.07


0.8



0.1


1.0



1.5
Note 1: For all calculations, reference was made to the normal value.

3.2 Fluid Properties
The fluid properties for the Produced Water Transfer Pumps was taken from the Maximum Water
Simulation case, while the fluid properties for the Water Injection Booster pumps and Water Injection
pumps were taken from the Maximum Oil & Gas (Start-up) Simulation case.
The table below shows the fluid properties from the respective Heat and Material Balance (HMB)
Tables (Ref 4 & 5) which were used for the sizing.
Table 3: Fluid Properties
No. Description Tag
Flowrate
(m
3
/h)
Flowrate
(bpd)
Density (Kg/m
3
)
1
Produced water
transfer pump
44PA101A/B/C
(3x50%)
198.72 30,000 994.4
2
Water injection
booster pumps
29PA101 A/B/C
(3x50%)
132.40 20,000 1006
3 Water injection pump
29PA102 A / B
(2 x 100%)
264.80 40,000 1006













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3.3 ASSUMPTIONS
Assumptions were made on individual pump sizing which await the actual values from the isometric
drawing. Below are the series of assumptions.
3.3.1 Produced water transfer pump
Suction pipe length 10m
Suction static head 8m considering the vessel height.
Total K-factor (based on valves & fittings on the suction line) 6.89
Discharge pipe length based on 100ft (30.48m)
Discharge static head 10m
Total K-factor (based on valves & fittings on the discharge line) 2.89
3.3.2 Water Injection booster pumps
Suction pipe length 10m
Suction static head 8m
Total K-factor (based on valves & fittings on the suction line) 1.33
Discharge pipe length 10m
Discharge static head 10m
Total K-factor (based on valves & fittings on the discharge line) 4.74
A discharge pressure of 11 barg was used.
3.3.3 Water Injection pumps
Suction pipe length 10m
Suction static head 8m
Total K-factor (based on valves & fittings on the suction line) 0.637
Discharge pipe length 20m
Discharge static head 10m
Total K-factor (based on valves & fittings on the discharge line) 2.38










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3.4 CALCULATION PROCEDURE
The following methodology was used in performing the pump sizing / NPSH calculation
a. Pipe Data & Fluid properties was gathered
b. The absolute total pressure at pump suction was calculated.
c. The absolute total pressure at pump discharge was calculated.
d. The Differential head of the pumps was determined.
e. The pump hydraulic power was determined.
f. The pump actual horse power was determined.
g. The Net Positive Suction Head Available (NPSHA) was calculated.
Appendix I & II shows the detailed pump sizing calculation of the Produced Water transfer pumps,
Water Injection Booster Pumps and Water Injection Pumps.















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4.0 RESULTS / EVALUATION
A summary of the calculation result is giving in the table below.

Table 4: Summary of Results
Pump Parameters
Produced Water
Transfer Pump
(44PA101A/B/C)
Water Injection
Booster Pump
(29PA101A/B/C)

Water Injection
Pump
(29PA102A/B)
Differential Head (m) 28.668 84.068 1407.640
Flowrate (bpd) 32,998* 20,000 40,000
Hydraulic Power (hp) 22.73 40.85 1371.19
Estimated Horsepower
(kW)
19.51 35.60 1165.01
NPSHa (m) 37.84 48.02 128.99
Pump Efficiency 85.64 83.72 86.31
P / 100m
(bar)
Suction 0.02 0.025 0.025
Discharge 0.18 0.294 0.237
Velocity
(m/s)
Suction 0.84 0.7 0.8
Discharge 2.06 2.0 2.2

The pressure drop per length (P / 100m) values were obtained from the Process Calculation Report
(Ref 10) which captured all process lines inclusive of all pump suction and discharge lines.
*A flow margin of 10% was added to the produced water pumps.










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5.0 CONCLUSION
The results obtained from the pump sizing calculation as shown in Table 4, indicates that the
pump suction and discharge lines for the Produced Water transfer pumps, Water Injection Booster
Pumps and the Water Injection pumps adequately meet the specified criteria in section 3.1.
Appendix I & II show the detailed sizing calculation spreadsheets of the Produced and sea water
pump sizing respectively.














































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6.0 REFERENCES:
1. Basis of Design Etan Development - 325300BGRB12000.
2. Process Design Philosophy - 4295-BWO-P-FD-00001.
3. Produced water transfer Pumps P&ID 4295-IESL-P-XB-44005.001.
4. Heat & Material Balance for Maximum Oil & Gas (Start-up).
5. Heat & Material Balance for Maximum Water Case.
6. Water injection booster pumps P&ID - 4295-IES-P-XB-29004.001.
7. Water injection pumps P&ID 4295-IES-P-XB-29005.001.
8. API 14E Recommended Practice for Design & Installation of Offshore Petroleum
Production Platform Piping Systems (Section 2.3b).
9. Eni Exploration & Production Design Criteria (10009.HTP.PRC.PRG) Process
Minimum Requirement
10. Process Calculation Report (XXX-IES-P-DOC-002)




































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APPENDICES































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APPENDIX I
Produced water pump sizing calculation































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APPENDIX II
Water Injection Pumps Sizing Calculation



























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APPENDIX III
Heat & Material Balance For Maximum Oil & Gas (Start-up)




























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APPENDIX IV
Heat & Material Balance For Maximum Water Case
































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