SHELL PETROLEUM DEVELOPMENT COMPANY

CONCEPTUAL DESIGN FOR CAWTHORNE CHANNEL GAS

INJECTION / SUPPLY PROJECT




FUNCTIONAL SPECIFICATION
FOR
EXPORT GAS COMPRESSION AT CAWTHORNE CHANNEL GAS
PLANT






B1 15.09.99 ISSUED FOR EPC TENDER J .B. NITZSCHE F. J . SHAW E. A. AKINSIPE T. DU-FRAYER
A3 29.06.99 RELEASED A. LENEVEU A. LENEVEU P. KERGUSTANC E. W. OBOTT
A2 17.06.99 ISSUE FOR APPROVAL A. LENEVEU A. LENEVEU P. KERGUSTANC E. W. OBOTT
A1 04.05.99 ISSUE FOR COMMENT A. LENEVEU A. LENEVEU P. KERGUSTANC E. W. OBOTT
REV DATE REASON FOR ISSUE PREPARED CHECKED APPROVED APPROVED
NETCO/TECHNIP GEOPRODUCTION
NTPG
DISCIPLINE
ENGINEER
DISCIPLINE
CHECK
PROJ ECT
MANAGER
QA
2 AJ OSE ADEOGUN STREET
PO BOX 74173 VICTORIA ISLAND
LAGOS
SPDC APPROVAL SIGNATURE:
2 AJ OSE ADEOGUN STREET
PO BOX 74173 VICTORIA ISLAND
LAGOS
Document No.: CCGP-SF-P-011 REV B1
FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


CCGPSFP011B1 Page 2 of 7 Revision: B1

TABLE OF CONTENTS



1.0 GENERAL

2.0 PROCESS DESCRIPTION

3.0 SYSTEM LIMITS & INTERFACES

4.0 RELIEF AND BLOWDOWN

5.0 PERFORMANCE REQUIREMENTS

6.0 INSTRUMENTATION AND ELECTRICAL

7.0 MATERIALS REQUIREMENTS

FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


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1.0 GENERAL

1.1 Introduction

This specification describes the functional requirements for the export gas
compression system of Cawthorne Channel Gas Plant in the Cawthorne
Channel Gas Injection/Supply Project.

The main objective of the function is to compress associated gas from 2
pressure levels (LP: 3.5 bara, HP: 9.1 bara) up to 111 bara for export via a
manifold to various users.

1.2 Reference Documents

SPDC Specifications
SPDCE-AGP-001 DEP and SPDC standards to be used for Associated
Gas Projects
SPDCE-AGP-009 Common Design Philosophy
Project Specifications/Documents
COMM-ST-P-002 Process Control Philosophy
CCH-SP-M-005 Mechanical design Specification for GT driven
Centrifugal Compressor Packages
Process Flow Schemes Cawthorne Channel Gas Plant
CCGP-DW-P-101 Compression Facilities
CCGP-DW-P-101 Dehydration & Export
Process Engineering Flow Schemes Cawthorne Channel Gas Plant
CCGP-DW-P-211 1
st
Stage Suction Scrubber & Compressor
CCGP-DW-P-212 1
st
Stage Aftercooler
CCGP-DW-P 213 2
nd
Stage Suction Scrubber & Compressor
CCGP-DW-P 214 2
nd
Stage Aftercooler
CCGP-DW-P 215 3
rd
Stage Suction Scrubber & Compressor
CCGP-DW-P 216 3
rd
Stage Aftercooler & Disch. Scrubber
CCGP-DW-P 217 4
th
Stage Suction Scrubber & Compressor
CCGP-DW-P 218 4
th
Stage Aftercooler & Disch. Scrubber

2.0 PROCESS DESCRIPTION

The gas compression facilities at Cawthorne Channel consist of two
compression trains (2 x 50% capacity) driven by gas turbines of
approximately 13MW ISO rating each. The trains each consist of four
stages with associated aftercoolers and scrubbers. Between third and
fourth stages, gas is routed through two dehydration units (2x100%) which
are described in functional specification for Gas Dehydraton at Cawthorne
Channel Gas Plant CCGP-SF-P-013. Following dehydration, the (rich)
gas is routed to the nearby Global Energy Recovery Ltd. (GERL) facility,
where condensates are removed from the gas. The lean gas is
subsequently returned from GERL to the 4
th
stage suction of the export
compressors, at essentially the same pressure level as at 3
rd
stage
FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


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discharge. The GERL facility can be bypassed such that the gas from
downstream the TEG contactor can be routed directly to the 4
th
stage
suction of the export compressor. The 4
th
stage suction gas mole weight
can thus vary very considerably, and quite instantaneously, due to a trip at
GERL.

The gas separated in the existing LP and HP separators at the Cawthorne
Channel flow stations CCH1, CCH2 and CCH3 is routed to respectively
the inlet of the 1
st
and 2
nd
stages of the export compressors.

Each stage, including the fourth, has a suction scrubber to remove
entrained liquids from the suction feed. Suction scrubbers will be single
stage vane pack separators with schoepentoeter inlet devices. The 3
rd

and 4
th
stages have a discharge scrubber fitted with demisters.

The gas from each compressor discharge is cooled by an air-cooled
aftercooler, rated to cool the compressed gas to 41
0
C (a 10
0
C approach to
the mean maximum ambient temperature of 31
0
C). Each aftercooler will
cool the gas to a specified temperature to prevent hydrate formation within
the process and, for the 3
rd
stage, to operate the TEG contactor at a
constant temperature of 45C, at the maximum ambient temperature of 35
0
C. The 1
st
, 2
nd
and 4
th
stage aftercoolers will achieve this by means of a
temperature-controlled bypass around the cooler. The 3
rd
stage
aftercooler will use temperature controlled variable speed fans, as hydrate
formation across the cooler is of concern at reduced flows through the
cooler.

The compression ratio of each stage will be selected such that discharge
temperatures do not exceed 170
0
C during normal operation. Although
slightly higher temperatures can be tolerated under transient conditions,
prolonged operation at temperatures above 170
0
C is not desirable and is
not permissible if coking is predicted.

The compressor is to be fitted with tandem dry-running gas seals, which
will use process gas taken from the compressor at a suitable pressure
level as the primary buffer gas. Secondary (barrier labyrinth) buffering will
be by air from the plant instrument air system.

Compressor capacity control will be based on suction pressure control
with discharge pressure override. It will be achieved by means of speed
control of the gas turbine driver, with corrections for imbalance between
LP and HP gas availability being made by individual stage recycle. Each
stage of compression of each train will have a dedicated capacity control
recycle valve, except the 2
nd
and 3
rd
stage, which may have a shared
capacity control recycle valve.

The compressor discharge pressures of the 3
rd
and 4
th
stages are
maintained at a constant value by a pressure controller downstream of the
TEG contactor and at the export gas metering respectively.

Capacity control is achieved primarily by speed control, supplemented by
recycle, and overridden by discharge pressure control. If 1
st
, 2
nd
or 3
rd

FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


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stage suction pressure increases, the relevant separator, and upstream
stage, supply more gas than is being compressed. The recycle valve, if
open, will close and, if suction pressure is still rising, the speed will
increase until either maximum speed or maximum discharge pressure is
reached. If suction pressure still increases, the gas available exceeds the
compressor capacity and the spillover valve to flare on the relevant
separator outlet will open to flare the excess gas.

In case of falling suction pressure, the spillover valve to flare closes, the
speed reduces and, on reaching minimum, the recycle valve opens.

The performance controller will determine the compressor speed based on
the highest supply available from any of the separators. For instance, if
the HP separator (2
nd
stage suction) pressure is falling (due to shutting in
of some HP wells), the speed will not be reduced (to avoid unnecessary
flaring of LP gas), but only the 2
nd
stage recycle will open. A station
performance controller will ensure that the required compression load is
shared equally by the two export trains.

Each compressor stage is protected by a dedicated anti-surge controller
and valve.

Surge and capacity control of the 4
th
stage of compression will merit
particularly careful review in view of the possibility of sudden mole weight
changes due to a process upset at GERL.

The temperature at the outlet of the capacity and surge control recycle
valves is controlled by upstream injection in the recycling line of hot gas
taken at compressor discharge before cooling.

3.0 SYSTEM LIMITS AND INTERFACES

Content and limits of the gas compression packages, for what is directly
related to process are shown on PEFs quoted in paragraph 1.2
hereabove, and are as follow:
LP gas inlet
HP gas inlet
Gas to the dehydration manifold
Gas from the dehydration manifold/from GERL
Gas to the export gas manifold
Vent/relief/blowdown to the HP flare header
Vent/relief/blowdown to the LP flare header
Drains to the process drains system
Drains to the closed hazardous drains system

Site conditions are described in document No.SPDCE-AGP-009 Common
Design Philosophy. Fuel gas treatment system is described in functional
specification No CCGP-SF-P-016.

FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


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Electric power is provided from the electrical distribution system for the GT
starter motor (if gas expanders are not used) and compressors and GT
auxiliaries. Emergency source to be provided for the pre/post lube pumps
as needed.

Main shutdown valves (UZVs) at inlet to each stage (apart from third) of
the gas compression trains, and at the outlet of 3
rd
and 4
th
stages, are to
be located externally of the gas compression skids.

4.0 RELIEF AND BLOWDOWN

Blowdown will result automatically from an ESD signal or it can be initiated
manually from the control room. Emergency depressuring system shall be
designed according to Shell DEP 80.45.10.10-Gen.

Relief provisions are included in the gas compression package, as shown
on PEFS for fire protection of the vessels, or overpressure due to blocked
line as necessary.

5.0 PERFORMANCE REQUIREMENTS

The compression system shall be able to compress the full range of
process fluids specified in the Process Flow Schemes quoted in Section
1.2 above, between 0% and 100% of the rated capacity. For the 4
th

stage, this shall include the gas composition for all cases, with and without
condensate recovery by GERL.

The required discharge pressures specified in the above mentioned PFSs
shall be attained at 100% speed, as defined per API 617 paragraphs 1.4.4
and 1.4.15, for any of the gas compositions specified.

The compressor package shall deliver gas from the 3
rd
stage at a constant
temperature of 45 C at a maximum ambient temperature of 35 C in order
to satisfy TEG contactor requirements.

6.0 INSTRUMENTATION AND ELECTRICAL

The instrumentation requirements are shown in the PEFSs referenced in
Section 1.2 and the control philosophy is described in the Process Control
Philosophy (COM-ST-P-002). All process control instrumentation is
generally routed via the central control room, but local loops incorporating
local controls may be used where applicable.

6.1 ESD/OSD Functioning

In addition to the normal ESD 1.0 signals, e.g. fire and gas detection, loss
of instrument air etc., operational shutdown of the compressor itself will
occur in the following situations:

High-high liquid level in any of the scrubbers
High-high temperature at the discharge of each compression stage
High-high temperature at the outlet of 3
rd
and 4
th
stage aftercoolers
Low-low pressure at the suction of each compression stage
FUNCTIONAL SPECIFICATION FOR EXPORT GAS COMPRESSION AT CAWTHORNE
CHANNEL GAS PLANT


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High-high pressure at the discharge of each compression stage
Low-low temperature at the discharge of the 3
rd
stages of intercooling
Equipment protection system

6.2 Hazardous Area Classification

The compressors create a Zone 2 hazardous area all auxiliary
equipment installed within 3 meters shall be suitable for use in a Zone 2
classified area, Gas Group IIA, Temperature Class T2 minimum. In
addition, instrumentation must meet the requirements of Zone 1, Gas
Group IIC, Temperature Class T3 minimum.

7.0 MATERIAL REQUIREMENTS

All materials of construction within the compression package should be
adequate to meet the projects 20-year lifecycle requirement for the full
range of process fluids and environmental conditions specified.

For full details of piping material requirements, see the Project
Specification for Piping and Valves CCGP-SP-L-001 and PEFSs
referenced in section 1.2.