SAES-A-010.pdf

Engineering Standard SAES-A-010

26 February 2013

Gas Oil Separation Plants (GOSPs) Document Responsibility: Process Engineering Standards Committee

Saudi Aramco DeskTop Standards Table of Contents

1 Scope................................................................. 2 2 Conflicts and Deviations.................. Deviations...... .................... ................... ........... 2 3 References......................................................... 3 4 Definitions........................................................... 4 5 GOSP Product Specification................ Specification.... ................... .............. ....... 7 6 Overall Process Design.................. Design....... ..................... .................... .......... 8 7 GOSP Equipment Design Considerations ….... 10 7.1 Flowlines/Trunklines 7.2 Production Manifold 7.3 Production Separators 7.4 3-Phase Production Separators 7.5 2-Phase Production Separators 7.6 Charge Pumps 7.7 Crude Oil Dehydration/Desalting 7.8 Booster/Shipping Pumps 7.9 Gas Compression 7.10 Gas Conditioning 8 Auxiliary Auxiliary Systems................. Systems............................. ............................ ................ 21 8.1 Wash Water Systems 8.2 Chemical systems 8.3 Hot Oil Systems 8.4 Closed Drain System 8.5 Instrument and Plant Air Systems 8.6 In- Plant Piping

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Next Planned Update: 26 February 2018 Page 1 of 32

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Document Responsibility: Process Engineering Standards Committee Issue Date: 26 February 2013 Next Planned Update: 26 February 2018

SAES-A-010 Gas Oil Separation Plants (GOSPs)

Table of Contents (cont’d)

9 GOSP De-Bottlenecking............. De-Bottlenecking... ..................... ................... ........... ... 26 Appendix I – Simplified Schematic of Satellite On-Shore GOSP........................... 27 Appendix II – Simplified Schematic of Off-Shore GOSP......................................... 28 Appendix III – Simplified Schematic of Simple GOSP with Gas Compression ….… 29 Appendix IV-Simplified IV-Simplified Schematic Schematic of Complex Complex GOSP with Gas Compression and Crude Stabilization…………… .…….… 30 Appendix V – Simplified Schematic of Hot Oil System................. System............................. ........................... ............... 31

1

Scope 1.1

This Standard provides the minimum mandatory requirement for the design of a grass root Gas Oil Separation Plant (GOSP) with or without crude stabilization.

1.2

The standard also provides the minimum requirement for debottlenecking an existing GOSP.

1.3

The crude Oil stabilization, Produced water treatment & disposal and Heat Exchangers are excluded from the scope of this standard. Other support systems that are part of the GOSPs (e.g. Fire water system, Fire & Gas detection, Plant alerting & Alarm system, Safety equipment, Flare system, etc.) are also excluded from this this standard. These shall be referenced in the relavant SAESs.

2

Conflicts and Deviations 2.1

Any conflicts between this standard and other applicable Saudi Aramco Engineering Standards (SAESs), Materials System S pecifications (SAMSSs),
















2.2

3


Direct all requests to deviate from this standard in writing to the Company or Buyer's Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, P&CSD of Saudi Aramco.

References All referenced Specifications, standards, Codes, Forms, Drawings and similar material shall be considered part of this standard and shall be the latest issue (including all revisions, addenda and supplements unless stated otherwise). 3.1

Saudi Aramco References Saudi Aramco Engineering Procedures SAEP-14

Project Proposal

SAEP-250

Safety Integrity Level Assignment & Verification

SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

SAEP-354

High Integrity Protective Systems Design Requirements

SAEP-363

Pipeline Pipeline Simulation Simulation Model Model Development Development and Support

SAEP-364

Process Process Simulation Simulation Model Model Development Development and and Support

SAEP-1663

Design Guidelines for Gas Oil Separation Plant (GOSP)

Saudi Aramco Engineering Standards SAES-A-020

Equipment Specific P&ID Templates (ESPT)

SAES-A-400

Industrial Drainage Systems

SAES-A-401

Closed Drain Systems (CDS)

SAES-A-403

Off-Shore Platform Drainage Systems

SAES-B-006

Fireproofing for Plants

SAES-B-014

Safety Requirements for Plants and Operations Support Buildings

SAES-B-062

Onshore Well Site Safety Design Criteria for Pressure

















SAES-H-002

Internal and External Coatings for Steel Pipeline and Piping

SAES-J-005

Instrumentation Drawings and Forms

SAES-J-601

Emergency Emergency Shutdown Shutdown and Isolation Isolation Systems

SAES-J-901

Instrument Air Supply Systems

SAES-K-402

Centrifugal Compressors

SAES-L-100

Applicable Codes and Standards for Pressure Piping Systems

SAES-S-020

Oily Water Drainage Systems

SAES-Z-003

Pipelines Leak Detection Systems

Saudi Aramco Best Practices

3.2

SABP-A-015

Chemical Injection Systems

SABP-A-018

GOSP Corrosion Control

SABP-A-036

Corrosion Monitoring Best Practice

SABP-K-401

Site Performance Testing of Centrifugal Compressors

Industry Codes and Standards American Petroleum Institute API SPEC 12J

Specification for Oil and Gas Separators

Institute of Electrical and Electronic Engineers (IEEE) IEEE 519

4

Guide for Harmonic Control and Reactive Compensation of Static Power Converters

Terms and Definitions AC: Alternating Current AC/DC: Alternating Current/Direct Current AFD: Adjustable Frequency Drive

















CDS: Closed Drain System CFD: Computational Fluid Dynamics CML: Corporate Model Library Crude Types: (Degree API: Typical range for various Saudi Aramco crudes)

ASL

: Arab Super Light

(49-52º API)

AXL

: Arab Extra Light

(37-41º API)

AL

: Arab Light

(32-36º API)

AM

: Arab Medium

(28-32º API)

AH

: Arab Heavy

(26-28º API)

CSD: Consulting Services Department DCS: Distributed Control System Dehydrator: Electrostatic Coalescer for removal of majority of water and salt from Crude Oil. Desalter: Electrostatic Coalescer for removal of residual Water and salt from crude oil. (Identical to dehydrator). DBSP: Design Basis Scoping Paper Disposal Water: Treated produced water for downhole/surface disposal/injection DFD: Dual Frequency Desalter DF-LRC: Dual Frequency-Load Responsive Controller DPD: Dual Polarity Desalter E&P: Exploration and Production EIV: Emergency Isolation Valve EPD: Environmental Protection Department ESD: Emergency Shutdown ESI: Emulsion Separation Index to measure Emulsion Stability

















FEED: Front End Engineering Development

Ga s or water wells for production or Flowline: Pipelines connected to a single Oil, Gas Injection. Formation (Produced) Water: Water produced from Reservoir with Oil and Gas production FPD: Facilities Planning Department GOR: Gas Oil Ratio in Standard Cubic Feet Fe et of Gas per Barrel of Stock Tank Oil GOSP: Gas Oil Separation Plant

deh ydration/desalting, GOSP (Satellite): Onshore Gas Oil Separation Plant without oil dehydration/desalting, produced water separation and treatment facilities GOSP (Offshore): Offshore Gas Oil Separation Plant without oil dehydration/desalting, produced water separation and treatment facilities EPD: Environmental Protection Department H2S: Hydrogen Sulfide HP: High Pressure HPPT: High Pressure Production Trap (2 or 3-phase separator) Injection (Power) Water: Treated Sea Water or aquifer water for reservoir pressure support IPPT: Intermediate Pressure Production Trap (2 or 3-phase separator) L/D: Length to Diameter Ratio LPDT: Low Pressure Degassing Tank (2 or 3-phase separator)

3-ph ase separator) LPPT: Low Pressure Production Trap (2 or 3-phase MBCD: Thousand Barrels per Calendar Day MBOD: Thousand Barrels per Operating Day

MBOD= MBCD/Overall Operating Factor



















MOV: Motor Operated Valve OOK: Out of Kingdom OSPAS: Oil Supply Planning and Scheduling Department Overall Operating Factor: Factor accounting for shrinkage and downtime (Fraction) PPM: Parts Per Million P&CSD: Process and Control Systems Department P&FDD: Production & Facilities Development Department PFD: Process Flow Diagram P&ID: Piping and Instrumentation Diagram PM&OU: Process Modeling & Optimization Unit Production Manifold: Piping manifold where all incoming Trunklines/Flowlines combine within the GOSP battery limit to feed the production Trap PTB: Pounds of salt per thousand Barrels of Crude oil Remote Production Manifold: Piping Manifold where Trunklines/Flowlines combine into one Trunkline outside the GOSP fence to feed the GOSP Production manifold RMD: Reservoir Management Department RVP: Reid Vapor Pressure Shrinkage: Decrease in oil volume caused by the evaporation of solution gas or by

















TVP: True Vapor Pressure (@ temperature) VSD: Variable Speed Drive Wash Water: Low salinity water used to wash the crude oil and dilute the formation water in the crude desalting process. Water cut (Percent): Produced water rate*100/(Crude rate+ Produced water Rate) Well-head Piping: Piping system connecting the well head to the flowline first isolation valve

water mainly from the WOSEP: Water Oil Separator. Collect and treat separated water 3-phase separators and dehydrator to remove the entrained oil before disposal to the reservoir.

5

GOSP Product Specification 5.1

Desalted Dry Crude - Salt-in-Crude to Pipeline: 10 PTB (Max) - BS&W to Pipeline:

5.2

0.2 Vol% (Max)

Stabilized Crude (for GOSPs with Stabilizers) - H2S in Crude:

70 PPM by weight (Max) 30 PPM by weight (Design conditions) 1-60 PPM by weight (Operating Range)

- True Vapor pressure

13 psia (Max) at export or storage temperature, (whichever is higher).















Document Responsibility: Process Engineering Standards Committee Issue Date: 26 February 2013 Next Planned Update: 26 February 2018 Note:

6


Maximum injection pressure is recommended to be below 3000 psig at disposal pump shut off so that 1500# rating disposal piping can be used.

Overall Process Design 6.1

The GOSP design shall progress through conceptual study, pre-DBSP study, DBSP approval, Project Proposal or FEED followed b y Detailed Design and construction. The data required to to conduct GOSP process studies during the the various phases shall be referred in SAEP-1663 SAEP-1663.. RMD/P&FDD shall provide provide the required data. The necessary Safety Reviews (HAZOP, SIL, Building Risk Assessment, etc.) shall be conducted per applicable sections of SAEP-14 of SAEP-14,, SAES-J-601,, and SAES-B-014 respectively. SAES-J-601

6.2

The Base Case production option and other alternative production Options shall be finalized in discussion with Upstream, P&CSD and FPD.

6.3

Simulations 6.3.1

Steady State Process simulation shall be based on the latest version of the approved simulation Software package based on SAEP-363 and SAEP-364.. The Process simulation software package that SAEP-364 that will be used in the project shall be concurred by P&CSD.

6.3.2

The GOSP simulations shall be carried out for summer and winter conditions at Design Water cut, initial Water cut and intermediate production phase.

6.3.3

The Gas compression simulations shall be carried out for summer and winter conditions. The gas compression to be sized on the controlling gas rates based on the simulations.

6.3.4

The Process simulation during the FEED and Detailed Design Phase
















6.4


6.3.7

Transient Dynamic simulations shall also be performed on parallel gas compression trains to confirm the functionality of the compressor control system during start-up, operating and shutdown conditions of individual or multiple gas compressors.

6.3.8

The Transient Dynamic simulations of the Gas compressors individually and combination of parallel trains shall be reviewed and approved by P&CSD/APSD/PM&OU. The final dynamic Simulation Models shall be delivered delivered to P&CSD’s CML coordinat coordinator or as part of the MCC.

PFDs 6.4.1

Preliminary PFDs showing the heat & material balances for Summer and Winter conditions of the GOSP and the crude stabilizer (if included in the GOSP) for the following conditions shall be developed: 6.4.1.1

Design Water Cut

6.4.1.2

Initial Water cut

6.4.1.3

Final Water Cut

6.4.2

The Preliminary PFDs showing the Heat & Material Balances for Summer and Winter conditions shall be develope d for the Gas compression. Preliminary gas export pipelines pressure pressure shall be available to determine the Gas compression HP requirement.

6.4.3

Energy System Optimization Assessment study shall be conducted based on the preliminary PFDs per SAEP-14 per SAEP-14.. The energy optimization shall satisfy all operating conditions for summer, winter and the life cycle of the project per paragraph 6.8.1.
















Gas Oil Separation Plants (GOSPs)

b)

Control Valves- Tight Shut-Off requirement

c)

Level Transmitter- Type of level transmitter, Calibration Range

d)

Additionally, the vessel template shall show the various level alarm settings as height from vessel bottom for horizontal vessels and Tan line for Vertical Vertical vessels. Level alarm settings shall shall be shown as actual levels (instead of percentages) in DCS block or display.

e)

Level Gauge: Type of Level Gauge, backlighting requirement

f)

Temperature Transmitter- Type of TT and Range. Alarm setting on the DCS block or display

g)

Temperature Gauge- Range of Temperature Gauge

h)

Pressure transmitter/gauge- Range of the pressure transmitter/gauge. Alarm settings on the DCS block.

i)

All shutdown switch settings

j)

All shutdown Alarms shall be shown connected to the Sequence of Events Recorder.

Note:

7

SAES-A-010

The above required instrument details can be included in SAES-J-005 .

6.10

All the GOSP shall be designed for 40% turndown. For GOSPs with crude stabilization, the stabilizer column turndown will be the controlling factor for the GOSP turndown.

6.11

All GOSPs shall be designed for Wet Sour Service Service for for potential souring of the production field during the life cycle unless RMD recommends otherwise.

GOSP Equipment Design Considerations

















Document Responsibility: Process Engineering Standards Committee Issue Date: 26 February 2013 Next Planned Update: 26 February 2018 Note:

7.1.4 7.2


For existing Flowline/Trunkline networks, HIPPS to be evaluated in accordance with SAEP-250 SAEP-250 and and SAEP-354 SAEP-354 if the shut-in well head pressure exceeds the design pressure.

Slug flow in trunklines shall be avoided and slug mitigation measures to be provided to minimize production trap level and pressure upsets.

Production Manifold/Header 7.2.1

For new GOSPs the Production manifold and the production header to the last block valve to the inlet of the first production Separator (Trap) shall be designed for the maximum max imum shut-in pressure of the field including future artificial lift (Gas lift, ESP or multiphase pump). Note:

For existing GOSPs, HIPPS to be implemented at the subject wellheads that exceeds the design pressure of the production manifold.

7.2.2

Flowline/Trunkline connections to the Production Manifold shall be from the Top for new facilities.

7.2.3

As per RMD/P&FDD requirements, spare connections with blinds shall be provided on the production manifold for connecting future trunklines. To avoid dead legs, legs, the active trunklines trunklines to be connected at

















P&CSD and FPD based on life cycle economics during the initial field development study. 7.3.2

The flash stage pressures shall be based on Flowing well head Pressures, Individual stage GORs, reservoir production strategy over the field life and crude type to optimize production cost during the field life and maximize reservoir recovery. Note:

The number of flash stages increases at higher GOR and higher Flowing Well Head pressures to optimize the gas compression cost.

7.3.3

The number of flash stages and flash pressures shall be specified in the DBSP along with the flash stage descriptions.

7.3.4

The following requirements shall be met in all production Separators: 

The bottom of the feed inlet nozzle shall shall be at least 6” above the HH liquid level shutdown



Perforated (not Slotted) Anti-Wave baffles shall be provided.



Any internals for optimum separation efficiency shall be selected based on the results of the Computational Fluid Dynamic Model.

















minimize liquid carry over in the Gas. Liquid carry over in gas shall be less than 1 gal/MMSCF. 7.3.8 7.4

The design pressure of Tanks in low pressure production separation service shall be minimum 10 psig.

GOSP Three Phase Production Separators 7.4.1

The 3-phase Production Separator shall be designed for the design water cut or minimum 30% water cut whichever whichev er is higher.

7.4.2

Typical liquid retention (Holdup) time for water-oil separation shall comply with API standard, i.e., API Spec 12J.

7.4.3

The minimum seam-seam to Vessel Diameter ratio (L/D) shall be 7 for the horizontal 3-phase production separator vessel.

7.4.4

The water weir for the 3-phase production separator vessel shall be located at least one vessel diameter from the vessel v essel tan line.

7.4.5

The normal oil level in the 3-phase production separator vessel shall be at least 6”above the Weir top. The High-High Interface level alarm
















7.5


Two Phase Production Separators 7.5.1

The 2-phase production separator upstream of the crude oil dehydration/desalting train shall be sized for 30% water cut.

7.5.2

The minimum seam-seam to Vessel Diameter ratio (L/D) shall be 7 for the horizontal 2-phase production separator vessel.

7.5.3

The typical retention time (Hold up) for Gas-oil separation for 2-phase vessels are given in API SPEC 12J.

7.5.4

Following are the minimum surge time between the oil-level settings based on design flow rates:

7.5.5



Between High High Oil level shutdown and High Oil level alarm: 2 Minutes



Between High Oil level alarm and Lo Oil level alarm: 2 Minutes



Between Lo Oil level alarm and Lo Lo oil level shutdown: 1 minute

The selected 2-phase separator sizing shall be approved by P&CSD.

















or crude production interruptions during maintenance of one stage. 7.7.2

For GOSPs processing AM and AH crude grades minimum 3 stage dehydration/desalting shall be provided. Notes:

Two stage dehydration/desalting can be considered in AH and AM crude production with new technology internals provided the Vendor is guaranteeing the desalted crude specification with single stage operation at minimum 60% 60% dry crude throughput. The two-stage desalting in AH and AM crude service shall be concurred by both P&CSD and Operations. For ASL crude grade and Khuff gas condensate processing, the need of crude desalting to be evaluated based on the formation water TDS and Emulsion stability Index to meet the specification to the pipeline.

7.7.3

The dehydrator and desalter piping configuration shall be designed to operate with the any one vessel bypassed bypassed at a time. time. The bypass capability shall be provided for both vessels.

7.7.4

Where reservoir pressure support is provided by power water injection, the crude dehydration and desalting trains shall be designed for 30% water cut. Reduced trims to be installed on control control valves for better controllability during the initial production phase where the water cut



















- Dual Frequency Desalting: Desalting: Upgrade of Dual Polarity Desalting Desalting technology with Frequency modulation and Arc control. 0-30% water cut 7.7.8

Minimum two levels of charged grids (double volted) shall be provided for the AC field dehydrator/desalter in the production field. Single Volted Electrical grid configuration (Bottom grids charged and Upper Grid Grounded) shall not be used in the production field.

7.7.9

The electrostatic grids of AC field and DPD shall be charged by 3 single phase step-up transformers. transformers. The preferred primary supply voltage to the AC field and a nd DPD technology transformers is

















7.7.15

The entrance bushing standpipe shall be equipped with a transparent type level gauge and a sampling point for periodic sampling of the standpipe oil for analysis of di-electric constant on a quarterly basis as a minimum.

7.7.16

Emulsion Feed distributors shall be designed based on CFD modeling for uniform distribution of the feed over the electrical grid area and prevent channeling/ recirculation. The distance between the top of the feed distributor and bottom of the charged grids shall be minimum 3.3 feet (1 meter).

7.7.17

Electrical grid loading for the AC field desalting systems in the

















7.7.21

Two Transparent type interface monitoring sight glasses with backlighting shall be provided. The sight glasses shall be located at both ends of the vessel and directly connected to vessel nozzles taken from the side.

7.7.22

Level switch shall be installed and connected to to permissive circuit to ensure the vessel is filed with liquid before appl ying the power.

7.7.23

Internal floats shall be provided to ground the grids in case the crude oil level drops for AC field field and DPD technology. For DFD technology, external level switch to be connected to the ESD system to switch-off power in case of falling oil level.
















7.9


Gas Compression 7.9.1

Each GOSP gas compressor shall be provided with its own suction drum, after cooler and compressor discharge KO d rum. Notes:

7.9.2

Individual Compressor discharge drum can be deleted in lean gas compression where negligible liquids are formed after cooling.

Compressor suction drum shall be equipped with mist eliminator to remove 99.99% liquid droplets of 6 microns and larger. Fiber Glass or other synthetic coalescing packing shall not be used in the compressor suction drums. Large capacity HP gas compressors suction drums in in the GOSPs shall be equipped with “V” type mist eliminator.

















7.9.9

Fixed speed motors of Spheroid and LP gas compressor shall be sized to start the compressor at normal operating pressure. Refer SAES-K-402 Refer SAES-K-402 for start-up capability requirements of fixed speed motors for low suction pressure gas compressors.

7.9.10

Field performance testing shall be conducted on all new process gas compressors within 6 months of start-up or immediately after overhaul to establish the baseline performance per SABP-K-401 per SABP-K-401.. Compressor performance testing to repeated on a 3-6 years interval in GOSPs. All compressor performance records shall be maintained by the respective plant engineering Unit.


















7.10.6


Gas Dehydration standard is under development by P&CSD / UPED / GPU.
















8.1.8


Sand/sludge recovery system shall be provided on the water jetting effluents from the dehydrator/desalter.
















SABP-A-018 and SABP-A-036 SABP-A-036..


















coke build up tendencies besides process heating requirements. Auto ignition temperature of the heating media shall be at least 50C above
















8.5

Instrument Air/ Plant Air systems














































































SAES-A-010.pdf

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