8015-0151-TOYO-00-000-PC-BD-00002_02

Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02

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WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

TABLE OF CONTENTS 1.

INTRODUCTION ........................................................................................................ 5

2.

SCOPE ....................................................................................................................... 5 2.1.

3.

4.

5.

6.

7.

Abbreviation

6

WELL PAD PRODUCTION FACILITIES ................................................................... 6 3.1.

Well Pads

6

3.2.

Well Heads

7

3.3.

Well Pad Manifolds & Multi-Port Flow Selector Valves

8

(12-1XX-00-PK-010/011/012/013) (‘XX’ = well pad number)

8

3.4.

Protection against Over-pressurization

9

3.5.

Chemical Injections

9

3.6.

Instrument Air Package & Receiver

10

3.7.

Closed Drain

10

3.8.

Nitrogen supply

10

3.9.

Trunk Lines

10

INLET MANIFOLD SYSTEM (UNIT 201) ................................................................. 11 4.1.

Process Description

11

4.2.

Basic Design Criteria

11

4.3.

Battery Limit

13

GAS / OIL SEPARATION SYSTEM (UNIT 210) ...................................................... 13 5.1.

Process Description

13

5.2.

Unit Capacity

14

5.3.

Design cases

14

5.4.

Basic Design Criteria

14

5.5.

Battery Limit

16

OIL DESALTING SYSTEM (Unit 215)..................................................................... 16 6.1.

Process Description

16

6.2.

Unit Capacity

17

6.3.

Basic Design Criteria:

17

6.4.

Battery Limit

17

OIL STABILIZATION SYSTEM (Unit 220) .............................................................. 19 7.1.

Process Description

19

7.2.

Unit Capacity

19

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WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

7.3.

Basic Design Criteria

19

7.4.

Battery Limit

20

FUEL GAS SYSTEM (SYSTEM 350) .................................................................................... 21

8.

7.5.

Process Description

21

7.6.

Equipment for Full Field Development

21

STORAGE & PUMPING FACILITIES (UNIT 410) ................................................... 22 8.1.

Process Description

22

8.2.

FEED and PRODUCTS

23

8.3.

Basic Design Criteria

23

8.4.

Battery Limit

26

OIL TRAINS CLOSED DRAINAGE SYSTEM (UNIT 451) .................................................... 27

9.

10.

8.5.

Process Description

27

8.6.

Unit Capacity

27

8.7.

Basic Design Criteria

28

8.8.

Battery Limit

29

EXPORT OIL FISCAL METERING SYSTEM (UNIT 468) ....................................... 30 9.1.

Process Description

30

9.2.

Basic Design Criteria

30

9.3.

Battery Limit

30

OIL TRAINS CHEMICAL STORAGE AND INJECTION (UNIT 490) ....................... 31 10.1.

Process Description

31

10.2.

Unit Capacity

31

10.3.

Basic Design Criteria

31

10.4.

Battery Limit

31

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

ISSUE NOTE

Rev.No.

Date

Made By

Page No.

Description

B

25/Jan/2013

Y.Y

-

Original Issue

C

21/Mar/2013

A.G

5 to 33

Issued for Approval

00

03/Jul/2013

A.G

All pages

Approved for Design

01

06/Dec/2013

AVG

5 to 7 & 10 to 12

02

19/Dec/2013

AVG

6

Updated for well pad-3 split Updated scope of work

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

1.

INTRODUCTION The objective of this document is to define the design basis for the central processing facilities (CPF Mishrif) to be installed in West Qurna Oil Field to meet the Full Field Development of 550,000 BOPD including 15% overdesign. The aim of the Central Processing Facilities is to receive and separate the gas, oil and water produced from the Mishrif fields. The stabilized crude oil is sent through a pipeline to a tank farm outside the CPF. Maximum oil processing capacity, in Full production phase (Phase 3), will be of 550,000 BOPD including 15% overdesign, achievable by a total of 11 crude oil trains (10 in operation + 1 stand by). While the existing facitlities which have been constructed for Early Oil Production (phases 1, 2) are not in the scope of CONTRACTOR, the new additional facilities for Full Field Development (Phase 3) is the scope of the CONTRACTOR.

2.

SCOPE The West Qurna-2 Mishrif Oil field area is located in the Southern Iraq, near the Euphrates and the Tigris confluence. The West Qurna-2 Project is divided into three phases: − Phase 1 – Crude Production Capacity of 150,000 BOPD plus 15%. In this phase, three (3) crude oil trains will be in operation. − Phase 2 – Crude Production Capacity of 400,000 BOPD plus 15%. In this phase, eight (8) crude oil trains will be in operation plus one (1) train as spare. − Phase 3 – Crude Production Capacity up to 550,000 BOPD including 15% overdesign. In this phase, ten (10) crude oil trains will be in operation plus one (1) train as spare. The separated HP gas from Inlet Manifold System (Unit 201) shall be transported to Gas Treatment Plant using raw gas compressors (by others).The treated gas coming from the Gas treatment plant (GTP) will be sent to a LP fuel gas KO drum to generate LP fuel gas to be used as fuel source for Hot-Oil fired heaters (existing), for blanketing oil storage tanks and as a purge gas for flare, the rest of the gas from the GTP will be directed to the gas turbine generators (GTGs) in FFD phase.The separated MP/LP gas from Oil Separation System (Unit 210) and Oil Stabilization System (Unit 220) will be supplied to Gas Treatment Plant via the raw gas compressors (by others). In the CPF Mishrif process, the following units are included in the scope of this document: • Well Pad Production Facilities - Tie-in of FFD well pads (new) to the existing EO well pads # 2, 5, 7, 8, 10, & 12. - New well pads #1,3-1,3-2,4,9 & 13 - Gathering System (Unit 622)

• Crude Process TOYO ENGINEERING CORPORATION

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-

Inlet Manifold System (Unit 201) Gas/Oil Separation System (Unit 210) Oil Desalting System (Unit 215) Oil Stabilization System (Unit 220)

• Fuel Gas System (Unit 350) • Facilities - Storage & Pumping Facilities (Unit 410) - Oil Train Closed Drainage System (Unit 451) - Export Oil Fiscal Metering System (Unit 468) - Oil Trains Chemical Storage and Injection (Unit 490) 2.1.

Abbreviation BOPD HP MP LP CPF LLP HC LPG KO NPSHa MAOP BOD COD R.V.P. IBP FBP

3.

Barrels Oil Per Day High Pressure Medium Pressure Low Pressure Central Processing Facility Low Low Pressure Hydrocarbon Liquefied Petroleum Gas Knock out Net Postitive Suction Head Available Maximum allowable operating pressure Biological oxygen demand Chemical oxygen demand Reid vapor pressure Initial Boiling Point Final Boiling Point

WELL PAD PRODUCTION FACILITIES 3.1.

Well Pads The Well Pad development comprises of the new well pads #1, #3-1,#3-2 #4, #9 and #13 and #11/1A (by others), apart from the new wells of the existing well pads #2, #5, #6, #7, #8, #10 and #12, total 13 Well Pads in Phase III. Each Well Pad consists of the followings: Well head (NOT in scope of CONTRACTOR) -

Electrical submersible pumps (NOT in scope of CONTRACTOR)

-

Well head control panels incl. hydraulic power units

-

Multi-port flow selector package (including multi-phase flow meter)

-

Instrument air system

-

Closed drain system

-

Chemical injection packages TOYO ENGINEERING CORPORATION

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The number of well heads, for each of the well pads which are involved in the Phase III is as follows:

Number of wells connected

Wellpad

Phase1 & 2

Phase 3

Total

1

0

12

12

2

13

11*

24*

3-1

0

12**

12**

3-2

0

11**

11**

4

0

29

29

5

14

7*

21*

6

11*

0

11*

7

13

13

26

8

13

7

20

9

0

26

26

10

14*

11*

25

11/1A

8 ( by others)

0

8 ( by others)

12

5

13

18

13

0

22

22

Total

91

174

265

* Per latest production profile (Production Profile Rev 3), Input data of Mishrif production rates 550MBOPD 27-01-2013) **As per revised production profile for WP #3-1 & WP #3-2

3.2.

Well Heads The well heads (Christmas trees – not in scope of CONTRACTOR) contain a subsurface shut-down valve (SSSDV), a surface shut-down valve (SSDV) and a choke valve supplied by COMPANY. Downstream of the choke valve, an additional ESD valve is installed as a substitute for a wing valve that is supplied by COMPANY. Well shut-in pressure, in case of the SSDV and the ESD valve downstream of the choke valve close, is given as 142 barg at the well head. In case of fire - detected by a fusible plug - the SSSDVs of the concerned well head and the neighbouring well heads close. There is one hydraulic power unit for four well heads, delivering hydraulic power to the 4 SSSDVs , 4 SSDVs and four of XV353 which are located on gas equalizing line. Each well head can be operated with a wellhead control panel 12-1XX-00-PK-100-LP-0YY (XX=well pad no.; YY=consecutive no. for well identification), which is installed one per four well heads. TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Control of the production from each well is achieved by the choke valve, a multi-position throttling valve,supplied by COMPANY. Its opening position is controlled through motor-operated mechanism, based on production targets defined for the wells and on results of well testing. Chemical injection packages 12-1XX-00-PK-001, -004, -005 (XX=well pad no.) provide adequate chemicals, injected in the production fluid. Injection points for chemicals are provided as follows: -

Corrosion inhibitor - injected downstream of choke valve

-

Scale inhibitor - injected downhole

-

Asphaltene inhibitor - injected downstream of choke valve

On each well pad, batteries of eight production wells 1XX-YY-Z-001 (XX=well pad no.; YY=consecutive no. for well identification) are connected to the production manifold. 3.3.

Well Pad Manifolds & Multi-Port Flow Selector Valves (12-1XX-00-PK-010/011/012/013) (‘XX’ = well pad number) The purpose of the manifolds is to connect the flowlines coming from the wells with the main header to the trunk lines. Also, the protection against over-pressurization is located downstream of the manifolds. There will be two types of manifolds on the well pads in EO Phase Production manifolds The production manifolds will connect the incoming flow lines from each well head with the outgoing trunk lines. A grouping of eight well heads consists of one production manifold. -

Test manifolds The testing manifolds will connect the incoming flow lines from each well head with the multiphase flow meter. For the FFD well pads and new wells added to the existing EO well pads a multi-port flow selector valve will be provided. In this piping configuration, 8 wells will be connected to a single MPFS manifold eliminating the need for dedicated test header and multiple on-off valves (XVs).

MPFS package will include a multi-phase flowmeter as an integral component inside the vendor supplied package. MPFS has 8 (eight) nos. of inlet connections. 1(one) outlet connection will be connected to production header and another outlet connection will be connected to test outlet feeding the multi-phase flow meter. During the oil production, it is important to gather reservoir information to enhance subsurface understanding, improve the fidelity of the reservoir models and to maintain the overall field material balance by defining the optimal position of the choke valve.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Therefore it is foreseen to install multiphase flow meters (one MPFM for 8 wells) to cyclically measure the gas production, oil production and the water cut of every well. The MPFM is capable of measuring following data:

3.4.

-

Oil flow rate

-

Water flow rate

-

Gas flow rate

-

Pressure

-

Temperature

-

Density

Protection against Over-pressurization Provisions for protection against over-pressurization allow designing the trunk lines with a design pressure that is lower than the well head shut-in pressure. The purpose of this protection is to protect the piping and equipment downstream of this high integrity pressure protection system (HIPPS) against over-pressurization without PSV installation. The sensors for this protection system are located at the well pad manifold, so that the trunk lines are safeguarded.When this protection system is activated, the emergency isolation valve starts closing, at a pressure of 35 barg as the trunk lines have a design pressure of 38 barg. This system is activated during emergency case, for instance, when pressure is increases higher than normal operating pressure. For FFD well pads and EO well pads with new well tie-ins using a MPFS manifold instead of conventional test and production headers configuration, a protection system with pressure sensors and activation of emergency isolation valve to safeguard the piping system will be provided downstream of each MPFS.

3.5.

Chemical Injections Refer to Drawing(s): 8015-0151-TOYO-12-100-PC-PF-00004 Chemicals are injected into the fluid stream for enhanced system operation. Scale inhibitor, corrosion inhibitor and asphaltene inhibitor are routed by one header per chemical to the well pad area and then are distributed by branches to each well head incl. flow indicator and manual needle valve. A pump spare capacity of 2 x 100% per skid and a chemical storage capacity of at least 14 days is considered.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

3.6.

Instrument Air Package & Receiver An instrument air package including 2 air compressors (1+1), filters and an air dryer is provided for each well pad. The produced air is supplied to the instrument air hold-up receiver, charging the instrument air distribution network. Refer to drawing(s): 8015-0151-TOYO-12-100-PC-PF-00006 Instrument Air Package (Well Pad) 12-1XX-00-PK-006 Instrument Air Hold-up Receiver (Well Pad) 12-1XX-00-V-002 (‘XX’ = well pad number)

3.7.

Closed Drain The closed drain system is used for collection of drains containing hydrocarbon liquids from lines, manifolds and equipment. These drains are sent to the closed drain drum. Refer to drawing(s): 8015-0151-TOYO-12-100-PC-PF-00006 Closed drain drum 12-1XX-00-V-001 (‘XX’ = well pad number) The closed drain drum is provided with one inlet. The vessel is designed as an atmospheric vessel (design pressure = 3.5/FV barg). The drum is sized for the liquid volume that can be produced by draining of lines or/and equipment during regular operation or maintenance activities, for instance, the emptying of the pig launchers. In case of extraordinary works, such as draining of the main header, much higher liquid volumes might be drained and one or more vacuum truck(s), which is in scope of COMPANY, have to be on site and empty the closed drain drum instantaneously. During pigging operation, a mobile flare shall be provided to prevent a fire case.

3.8.

Nitrogen supply Wherever nitrogen supply is needed for operation and maintenance activities (e.g. purging of pig launchers or well head piping), connections for nitrogen from pressurized nitrogen bottles have to be provided by COMPANY.

3.9.

Trunk Lines The trunk lines connecting the well pads to the CPF in EO phase (#2,#5,#7,#8,#10 & #12) will be tied-in with the new well pads (#1,#3-1, #3-2,#4,#9 & #13) in FFD phase. Pigging of the new trunk lines connecting the EO well pads will be accomplished using a dedicated pig launchers and receivers. Pigging is possible only in one direction; pig launcher will be installed on each FFD well pad and its corresponding pig receiver will be installed at the EO well pad that is connected to it.So that pigging operation can be performed periodically in a manual mode within the interconnecting trunklines at required intervals. TOYO ENGINEERING CORPORATION

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4.

INLET MANIFOLD SYSTEM (UNIT 201) 4.1.

Process Description The inlet manifold collects the well fluids (oil + gas+ water) from the trunk lines (during phase 3 for a maximum oil capacity of 550,000 BOPD including 15% overdesign). Due to different production rates of the well pads, a detailed study for the arrangement of the inlet manifold for optimum distribution of well fluid to the HP Separators was undertaken for the following well pad groupings; -

Well pads #4, #5 & #11/1A

-

Well pads #3-1, #3-2, #6, #9 & #10

-

Well pads #7 & #8

-

Well pads #1, #2, #12 & #13

The existing inlet separation system under EO phase has (3 + 1) trains of 8 HP separators (22-201-01-V-001A/B, 22-201-02-V-001A/B, 22-201-03-V-001A/B and 22-201-04- V-001A/B), which have been designed to separate oil and water up to 33% watercut for maximum oil capacity of 400,000 BOPD + 15% over design. HP separators (22-201-04-V-001A/B) have already been provided during Phase 1&2 for maintenance or pigging/ramp up case to hold the slug volume, so that the separation can be performed without the interruption of the supplement of crude oil to CPF. Under FFD phase, the existing inlet separators operating philosophy shall be changed to make sure all the four sets of HP separators operate without any spare to process the increased oil throughput of 550,000 BOPD.Inorder to handle water cut of upto max. 69.3%,2 sets of additional HP separators 22-201-01-V-001 C/D & 22-201-02-V-001 C/D will be required in the year 2031. HP gas separated from HP separators is sent to Feed gas compression system, which will be used for transporting raw gas from CPF to gas treatment plant (GTP) using multi-stage raw gas compressors (by others). The treated gas coming out of the GTP will be distributed to supply LP fuel gas to CPF users (Hot oil fired heaters, blanketing gas for oil storage tanks and as purge gas for flare) and gas turbine generators (GTGs). After separation of all inlet flows from wellpads through inlet separation system, the crude oil shall be collected and distributed to each crude processing unit (Unit 210). 4.2.

Basic Design Criteria The Inlet Manifold System is taking the following combinations of trunklines to ensure distribution of inlet fluid to each train of HP separator. The tables below are based groupings proposed by gathering system optimization concept proposed by COMPANY with fluid flows per production profile dated 27-Jan-2013.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Max. Gas flow rate (MMscfd)

Well Pads

Max. Oil flow (BOPD)

Max. Water flow (BWPD)

#4, #5 & #11/1A

188,630

365,792

2

#3-1, # 3-2, #6, #9 & #10

180090

3

#7 & #8

163,794

224,709

304,643

81

4

#1, #2,#12 & #13

169,660

275,915

426,521

83.92

Group No.

1

Max. liquid flow (BPD) 538,936

376935

521154

93.2

88.97

Group No.

Well Pad group

Max. water cut (%)

1

#4, #5 & #11/1A

67.87

Dec.2034

#3-1, # 3-2, #6, #9 & #10

72.3

Dec.2034

2

Overall water cut (%)

Date

69.40 3

#7 & #8

74.32

Dec.2034

4

#1, #2,#12 & #13

66.3

Dec.2034

Flow rate of each trunk line (at inlet temperature 60 °C and pressure 15 barg)

HP Separator is designed taking into consideration, the following criteria: The selected HP separator is 3 phase horizontal type. -

Two (2) separators to be considered for each Inlet Manifold and additional 2 sets for group 1 & group 2 based on HP separator study.

-

The allowed entrainments are:

-

Max Liquid Carryover in Outlet Vapors:

0.1 gallon/MMSCF

Max Water in Oil outlet:

10 % wt.

Max Oil in Water outlet:

2000 ppm

Vane type inlet device to be installed in order to prevent formation of waves, and promoted by surges of liquid incoming flows. TOYO ENGINEERING CORPORATION

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-

Vane type mist eliminator on the gas outlet is selected for high efficiency and reduced fouling tendency.

-

The sand jet system including mud wash header will be provided in order to wash out any sand or sludge which may accumulate in the vessel bottom.

-

Internals shall be accessible and removable through manway.

-

According to the fluid phases (gas, oil, water) entering the HP Separator, the control comprises:   

4.3.

Pressure control in the gas outlet section Level control of oil outlet Interface level control (to be implemented during FFD when water cut increases and separation is likely to also occur in HP Separator)

-

The maximum water content in oil is limited to 10% in weight as the downstream Gas/Oil Separation System (Unit 210) is designed to treat the crude oil with maximum water cut 10% wt. As it was expected that water cut would be less than 10% wt. during Phase 1 and 2, the separation of oil and water were not considered during EO phase. But during FFD, produced water from HP separators will be collected using interface level control techniques.

-

F.V. is considered when steam out is carried out @ 1 barg (120 oC)

-

Vortex breaker at oil outlet and water outlet should be installed.

Battery Limit Battery Limit conditions of streams entering and leaving Unit 201 are reported in following table: Temperature (°C) Operating Design

Fluid

Pressure (barg) Operating Design

Oil/water/gas from well pad

34-60

85

15

38

Oil to Unit 210

34-60

85

15

18

Gas to HP Flare / GTP

34-60

85

15

18

Unit 201 Battery Limit conditions

5.

GAS / OIL SEPARATION SYSTEM (UNIT 210) 5.1.

Process Description During Full Field Development project (Phase 3), additional two trains (No. 10 & 11) are provided, while there are identical nine trains that have already been provided during early oil production phase (Phase 1 & 2) with a combined sparing philosophy of (10+1).

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

The following description refers to a single crude oil treating line, which is the train 10, being identical for other train no.11. The gas/oil separation system receives live crude oil from the upstream Inlet Separation System, HP separator. The purpose of this Unit is to separate gas and remove produced water from the crude oil stream so that it can meet the vapor pressure and water content specification required for the downstream Oil Desalting System: in particular, water content must be reduced to 5% vol. to ensure a proper operation in the downstream Oil Desalting System (Unit 215), while gas separation allows reducing the live oil vapor pressure, and consequently the downstream desalting process operating pressure. The incoming crude oil stream is heated in the 1st Oil Heater (22-210-10-E-001) by the hot oil from 3rd oil heater (22-210-10-E-003) and then is discharged, under flow control, to the MP Separator (22-210-10-V-001). Temperature of the process stream entering the MP Separator (22-210-10-V-001) is controlled through a control valve in the Hot Oil bypass line by a direct action temperature controller. The water/oil/gas separation is performed in the MP Separator (22-210-10-V-001), which operates at 3.5 barg and 60°C. And the separated oil from MP Separator is pumped by the Desalter Package Feed Pumps (22-210-10-P-001A/B) to the Desalter Package (22-215-10-PK-001) in Unit 215 through 2nd Oil Heater (22-210-10-E-002 A/B) and 3rd Oil Heater (22-210-10-E-003). By 2nd and 3rd Oil Heaters, the temperature of crude oil is heated up to 104°C. 5.2.

Unit Capacity The capacity will be identical to all crude oil trains, and the design capacity of each one is 50,000 BOPD + 15% of Crude Oil. Crude Oil: 50,000 BOPD + 15% Max Water in Oil

5.3.

10 % wt.

Design cases Oil treatment facilities are designed to treat crude oil with composition and characteristics indicated in 8015-0151-TOYO-00-000-PC-DC-01001 (Basic Design Data) for FFD. The temperature for inlet fluid from well pads at CPF battery limit to be used for CPF design as follows: Water cut 0.4% : 34°C -

5.4.

Water cut 69.3% : 60°C

Basic Design Criteria The 1st Oil Heater is designed taking into consideration of the following criteria: The type is a shell and tube heat exchangers. -

It is designed to heat up to 60°C by hot oil coming from 3rd Oil Heater at the MP Separator inlet.

-

The maximum duty case corresponds to the initial years of operation of the CPF, in which the water cut is 0.4%.

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-

The maximum flow case corresponds with the case of Water cut 10% wt. in the feed to the CPF. This case sets the maximum pressure drop through the heater as the flow rate is a maximum and the viscosity is increased due to high water content.

The MP Separator is designed taking into consideration of the following criteria: The type of vessel is selected to 3 phase horizontal type. -

Vane type inlet device to be installed in order to prevent formation of waves, and promoted by surges of liquid incoming flows.

-

Vane type mist eliminator on the gas outlet is selected for high efficiency and reduced fouling tendency.

-

F.V. is considered when steam out is carried out @ 1 barg (120 oC)

-

MP Separator shall be designed to achieve the required separation between the three phases (gas, oil, water) under any of the operating conditions indicated here below. Two operating cases are to be considered depending on properties of formation fluid from wells: 

-

-

Maximum Oil Case: Maximum flow rate of oil to the MP Separator, which corresponds to the maximum oil processing capacity of a train. This case is determined according to the Heat and Material Balance for 69.3% HIGH WATERCUT CASE (8015-0151-TOYO-22-200-PC-HM-01001).  Maximum Gas Case: Maximum flow rate of gas to the MP Separator, which will occur at low operating temperatures in the Inlet Separation Manifold System. This case is determined according to the Heat and Material Balance for 0.4% LOW WATERCUT CASE (8015-0151-TOYO-22-200-PC-HM-01002). The allowed entrainments are: Max Liquid Carryover in Outlet Vapors:

0.1 gallon/MMSCF

Max Water in Oil outlet:

5 % Vol.

Max Oil in Water outlet:

1000 ppm

Vortex breaker at oil outlet and water outlet should be installed.

The Desalting Package Feed Pumps are designed taking into consideration of the following criteria: Centrifugal pumps to be installed. -

Pump design flow rate is the maximum operating flow plus a 10% overdesign.

-

Minimum flow line to be provided.

The 2nd and 3rd Oil Heater is designed taking into consideration of the following criteria: The type is a shell and tube heat exchangers. -

10% over design is considered in flow rates and duty. TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

-

Design pressure based on Desalting Package Feed Pump estimated pump shut-off pressure, to be confirmed by pump vendor. -

5.5.

Before entering the desalting system (Unit 215), the oil is heated up to reduce its viscosity and ensure a proper operation of the Desalter Package (215-10-PK-001). For this purpose, the oil is heated in two stages. In the first stage, in order to achieve acceptable RVP it is heated to about 81 °C in the 2nd Oil Heater (210-10-E-002 A/B) by heat recovery from the hot product stream leaving the Desalting Systems Unit. In the second heating stage, in order to satisfy viscosity at the inlet of the separator the oil is heated up to 104 °C in 3rd oil Heater (210-10-E-003) using Hot Oil as heating medium, and Hot Oil is then sent to 1st Oil Heater.

Battery Limit Battery Limit conditions of streams entering and leaving Unit 210 are reported in following table: Temperature (°C) Operating Design 34-60 85 104 120 100 120 70-78 120 58 85 33-60 85

Fluid Oil/water/gas from Unit 201 Oil to Unit 215 Oil from Unit 215 Oil to Unit 220 Gas to GTP Comp. Unit Water to Unit 484

Pressure (barg) Operating Design 15 18 14 24 11.5 24 5 24 3.5 5 3.5 5

Unit 210 Battery Limit conditions

6.

OIL DESALTING SYSTEM (Unit 215) 6.1.

Process Description The Oil Desalting system receives crude oil with about 5%vol. of produced water from the upstream gas/oil separation system. The purpose of this Unit is to remove salt in the incoming oil (which can be present in the oil phase as dissolved or suspended salt, and/or associated with water emulsified in oil) so that the treated oil can meet both the final salt and water content specifications. The oil/water emulsions are separated by the application of a high voltage electrostatic field inside the process vessels (Desalters) which promotes the coalescence of water droplets. Dilution Water Heater performs the heating up of service water fed as make-up to the desalting package (22-215-10-PK-001). Water removed in the 1st stage Desalter is cooled down by heat exchange with the fresh dilution water in the Dilution Water Heater (22-215-10-E-001), and sent to the Produced & Oily Water treatment Unit. The Oil Desalting System (Unit 215) is composed of the Desalting Package (22-215-10-PK-001), Dilution Water Heater (22-215-10-E-001) and one pump: Desalter Recycle Pump (22-215-10-P-001 A/B).

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

6.2.

Unit Capacity Unit 215 will be designed to process 50,000 BOPD + 15% of Oil in the formation fluid from wells, corresponding to the design capacity of each Crude Oil Train to be installed in the Mishrif CPF with a water cut up to 5% vol.

6.3.

Basic Design Criteria: Desalter package is designed taking into consideration of the following criteria: The proposed Desalting configuration consists of an electrostatic two stage Desalter system. -

The pre-heated oil coming from the Gas/Oil Separation System (Unit 210) at 13 barg and 104°C is mixed with water removed in the 2nd Stage.

-

Demulsifier is added to ensure good desalting performance, and then it is fed to the 1st Stage Desalter where most of the salty water is removed.

-

Outcoming oil from the 1st Stage Desalter is mixed with fresh dilution water (service water) pre-heated in the Dilution Water Heater (22-215-10-E-001).

-

After oil mixed with fresh dilution water, it is fed to the 2nd Stage Desalter where final water/salt removal is achieved.

-

Water removed in the 2nd Stage Desalter is recirculated to the 1st Stage Desalter by the Desalter Recycle Pump (22-215-10-P-001 A/B).

-

10% over design is considered in normal flowrate.

-

Maximum inlet salt content is 255 g/liter in produced water

-

Product characteristics are as following:   

Water content in outlet oil(% liq. vol): Max. salt content in outlet oil(PTB): Oil content in effluent water(ppm vol.):

0.2 ~ 0.4 10 250

Dilution Water Heater designed taking into consideration of the following criteria: Plate type heat exchanger is considered.

6.4.

-

Design pressure based on Desalting Package Feed Pump estimated pump shut-off pressure, to be confirmed by pump vendor

-

An integrated removable type filter shall be provided at each inlet of hot fluid side only.

-

Mesh size shall be lower than clearance between plates.

-

An overdesign factor of 110% for duty and flow rate shall be considered on the heat exchanger design. And it’s difficult to confirm the fouling resistance for produced water, so 15% overdesign is considered with clean condition.

Battery Limit Battery limit conditions of streams entering and leaving Unit 215 are reported in the following table: Fluid Oil from Unit 210

Temperature (°C) Operating Design 104 120

Pressure (barg) Operating Design 14.8 24

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Oil to Unit 210 Water to Unit 484

100 33 - 80

120 120

11.5 10.5

Unit 215 Battery Limit conditions

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24 24

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

7.

OIL STABILIZATION SYSTEM (Unit 220) 7.1.

Process Description The Oil Stabilization System receives desalted oil from the upstream Oil Desalting System (Unit 215). The purpose of this unit is to perform final oil stabilization so that it meets the minimum required product RVP (Reid Vapor Pressure) specification in export crude oil as well as TVP specifications for crude oil storage in external floating roof type storage tanks. For this purpose, the incoming oil is flashed at 0.7 barg in the LP Separator (22-220-10-V-001) in order to remove light components from the oil. Stabilized oil from LP Separator is pumped, under level control, to Storage & Pumping Facilities (Unit 410) by Stabilized Oil Pumps 22-220-10-P-001 A/B and it is cooled in the Stabilized Oil Trim cooler 22-220-10-E-001 A/B (using cooling water as heating medium) down to the storage temperature of 40 ~ 65 °C. In case that oil product to storage is off-spec (as detected by RVP analyser on crude oil line and higher temperature over 65°C), it is diverted to the off-spec / Slope Tank (22-410-00-TK-003 A/B) downstream the Trim cooler 22-220-10-E-001 A/B. De-gassed condensate stream (C5+) from GTP will be tied-in to the common stabilized oil manifold going to storage area. In case degassed condensate to storage is off-spec (as detected by RVP analyser on degassed condensate line), it is diverted to existing off-spec / slop tanks (22-410-00-TK-003 A/B). Considering the mercaptan levels in the stabilised oil, the feasibility of providing a mercaptan removal package shall be checked by the EPC contractor during detailed engineering stage to ensure max. RSH level of 40 ppm (wt.) in the stabilised oil.

7.2.

Unit Capacity Unit 220 will be designed to process stream 50,000 BOPD + 15% of oil. Lines and equipment in Unit 220 shall be designed considering a 10 % overdesign factor,

7.3.

Basic Design Criteria LP Separator is designed taking into consideration of the following criteria: The separator is a horizontal two phase oil/gas separator, provided with a boot to allow collection and drain off of water. -

The operating conditions for the flash have been satisfied the RVP (Reid Vapor Pressure) of maximum 10 psi.

-

LP Separator is designed to perform satisfactory gas-liquid separation and to provide a total liquid hold-up of 5 minutes between HLL and LLL.

-

Since water removal, in order to meet product specification, is performed in upstream Oil Desalting System, no continuous water drain off is expected.

-

An on/off level control is considered on separator boot to discharge possible collected water to closed drain system (Unit 451).

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

-

Inlet distributor equipped with short radius elbow and impingement plate to be installed in order to prevent formation of waves, and promoted by surges of liquid incoming flows.

-

Vane type mist eliminator on the gas outlet is selected for high efficiency and reduced fouling tendency.

-

Vortex breaker at oil outlet and water outlet to be installed.

-

F.V. is considered when steam out is carried out @ 1 barg (120 oC)

-

Max liquid carryover in vapour outlet shall be 0.1 gal/MMSCF.

-

An overdesign factor of 10% shall be considered in the design of the LP Separator

Stabilized Oil Pumps are designed taking into consideration of the following criteria: Centrifugal pumps to be installed. -

2x100% to be installed for 1 operating and 1 stand-by.

-

It shall be designed to pump stabilized oil from LP Separator to the Export Oil Storage Unit (Unit 410).

-

Pump is the maximum operating flow rate plus a 10% overdesign.

-

A minimum flow line to be provided.

Stabilized Oil Trim Cooler is designed taking into consideration of the following criteria: The type is a shell and tube heat exchanger using Cooling Water as cooling medium. -

7.4.

To be designed to ensure an operating temperature of 40 °C to Export Oil Storage Tanks in Unit 410. A 10% overdesign shall be considered in flow rate and duty. Design pressure based on Stabilized Oil Pump estimated pump shut-off pressure, to be confirmed by pump vendor

Battery Limit Battery Limit conditions of in/out streams of Unit 220 are reported in following table: Temperature (°C)

Fluid Cooled stabilized oil from 22-220-10-E-001 A/B Stabilized or Off spec oil to Unit 410 Gas to LLP flare Degassed condensate (C5+) from GTP

Pressure (barg)

Operating

Design

Operating

Design

40-65

90

5.2

16

40-65

90

5.2

16

72.5

90

0.7

3.5

60

135

7

16

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

FUEL GAS SYSTEM (SYSTEM 350) 7.5.

Process Description Refer to drawing(s): 8015-0151-TOYO-22-350-PC-PF-00001 Unit 350 is designed to receive the outlet gas from the GTP that will be distributed to gas turbine generators (GTGs) and the other plant users (purge gas for flare, tank blanketing etc.,) This unit is comprised of as-below (in EO phase); 22-350-00-V-002 (LP Fuel Gas K.O. Drum)

7.6.

-

22-350-00-E-001 (Fuel Gas Heater)

-

22-350-00-E-002 (Start-up Fuel Gas Heater)

-

22-350-00-E-003 (additional Fuel Gas Heater)

Equipment for Full Field Development During Full Field Development, two new oil trains #10 and #11 of Gas/Oil Separation system (Unit 210) are added, where additional hot oil heating is necessary to provide heat duty in 1st and 3rd oil heaters by fired heater. In order to achieve higher RVP for the stabilized oil from the third oil heater, the inlet temperature of the third oil heater is increased to 81 oC and hence decreasing heat duty of the 3rd oil heater and reduction of required hot oil flow rate. If the same operating philosophy has been applied for all the oil trains (in EO phase) then the existing hot oil system was found to be adequate to cater to the new oil heaters (1st and 3rd) in oil trains 10 and 11. Treated gas from GTP is supplied at an operating condition of @ 23.4 barg & 30 oC; Pressure reducing station has been considered to drop the pressure to LP knock out drum to ensure fuel gas is supplied to the downstream users at required pressure . The adequacy of fuel gas heater has been checked for the reduced temperature of 17.8 oC at the inlet of the fuel gas heater due to the pressure reducing station enroute to the LP flash drum. It was found to be inadequate. So, additional fuel gas heater identical to the existing one will be installed to meet the inlet temperature requirement of fuel gas to hot oil furnace per EO basis of hot oil furnace design. The start-up fuel gas heater has been retained. In case, GTP trips the treated gas requirements for all users is fulfilled by using CPF associated gas from HP gas manifold as per EO’s fuel gas supply philosophy. In FFD phase, additional HP gas manifold will be provided to ensure gas supply to GTP compression system at the required battery limit pressure. The existing LP fuel gas KO drum (22-350-00-V-002) size is verified for receiving the LP fuel gas from GTP and it was found to be adequate for revised gas flow.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Temperature (°C)

Fluid Treated gas from GTP

8.

Pressure (barg)

Operating

Design

Operating

Design

30

150

23.4

31

STORAGE & PUMPING FACILITIES (UNIT 410) 8.1.

Process Description The Oil Storage System is to store stabilized crude and to provide hold-up volumes during emergency case. Oil from Oil Storage System is boosted for export to Tuba Tank Farm after measuring the flow rate in a fiscal metering station. This unit comprises of the following tanks and pumps; 22-410-00-TK-001 A/B/C/D (Stabilized Oil Tank) -

22-410-00-TK-002 A/B (On Spec Oil Tank)

-

22-410-00-TK-003 A/B (Off Spec/Slop Tank)

-

22-410-00-P-001 A~E (Export Oil Booster Pump)

-

22-410-00-P-002 A~E (Export Oil Pump)

-

22-410-00-P-003 A/B (Off Spec/Slop Oil Pump)

-

22-410-00-V-001

(Storage Closed Drain Drum)

-

22-410-00-P-004

(Storage Closed Drain Pump)

Two additional stabilized oil tanks 22-410-00-TK-001C/D which will be installed in FFD phase to accommodate the increased stabilised oil throughput of 150,000 BOPD; other than this, there won’t be any additional required equipment under FFD. Export Oil from Oil Stabilization System is stored in Stabilized Oil Tanks 22-410-00-TK-001 A/B/C/D and On Spec Oil Tank 22-410-00-TK-002 A/B. According to the oil temperature from Oil Stabilization system, Export Oil is stored between Export Oil Tank and On Spec Oil Tank. In case that oil temperature is 40°C to 65 oC with stabilized crude corresponding RVP of less than 10 psi (0.68 bar abs), oil will be stored in Stabilized Oil Tanks (external floating roof type). If the oil is coming at the temperature of 40 ~ 65°C, it will be stored in existing on-spec Oil Tanks (dome roof type). In case of off-spec production in the Crude Oil Trains, Oil is routed to existing off-spec / Slop Oil Tanks (22-410-00-TK-003 A/B) after cooling in Stabilized Oil Trim Cooler (22-220-10-E-001 A/B). Off Spec Oil is then pumped back by Off Spec / Slop Oil Pump (22-410-00-P-003 A/B) to upstream of 1st oil heater (22-210-10-E-001) in order to be reprocessed. Off Spec / Slop Oil Tank (22-410-00-TK-003 A/B) will receive slop oil from CPF closed drain systems, from Stabilized Oil Tank (22-410-00-TK-001 A/B), from on-spec oil Tank (22-410-00-TK-002 A/B) and from flare K.O. drum. Also, the oil in Stabilized Oil TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Tanks and On Spec Oil Tanks can be transferred to Off Spec/Slop Tanks using export oil booster pumps when the stored oil in tanks is proved to be off-Spec oil by sampling. Export Oil Booster Pumps (22-410-00-P-001 A/B/C/D/E) take suction from Stabilized Oil Tanks and On Spec Oil Tanks. These pumps shall be provided to deliver the stabilized crude to Export Oil Pumps (22-410-00-P-002 A/B/C/D/E). Export Oil Pumps will deliver to Tuba Tank Farm. An underground horizontal Closed Drain Drum (22-410-00-V-001) will be installed. It will receive product from gravity drain lines and will collect product from thermal expansion valves located in the storage area. Oil stored in the Closed Drain Drum will be transferred to the Off Spec / Slop Tank (22-410-00-TK-003 A/B) by Closed Drain Pump (22-410-00-P-004). 8.2.

FEED and PRODUCTS The stabilized oil is fed from Crude Oil Trains, and stored in Export Oil Storage Tanks or On Spec Oil Tanks. The following properties have been considered: Product specifications

Values

RVP (psi) @ 38oC

10.0 max

H2S content

20 ppm (by wt) max.

Water content

0.2-0.4 vol%

Salt content

10 PTB (Pounds per thousand barrel)

RSH

40 ppm (by wt)

In case of off spec or slop oil, the oil is routed to Off Spec/Slop Tanks. The source of off spec or slop oil are as following: -

Off-Spec Oil from Crude Oil Trains

-

Oil from Closed Drainage System

-

HC Condensate from Flare K.O. Drums

-

Off-spec degassed condensate from GTP

The export oil pumped by Export Oil Booster Pumps and Export Oil Pumps shall meet the specification. The detail export oil specification refers to 8015-0151-TOYO-00-000-PC-DC-01001 (Basic Design Data).

8.3.

Basic Design Criteria Stabilized Oil Tank is designed taking into consideration of the following criteria:

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

-

Total Four identical tanks with external floating roof will be provided, while two tanks were already provided during early oil production phase, the other two tanks are being provided during Full Field Development phase.

-

EO production phase tank’s nominal capacity is 50,000 m3.

-

For the tanks added during FFD phase, the nominal capacity has been increased to 61904 m3, so as to compensate for the volume requirement of on-spec oil tank that was envisaged to be added.

-

The working volume equal to the EO on-spec oil tank has been accommodated in FFD stabilised oil tanks and no additional on-spec oil tank is been considered in the FFD phase.

-

Propeller Mixers will be fitted to tanks to ensure a homogeneous temperature and product distribution.

-

Sample valve STRAHMAN type or equivalent shall be provided at 1500 mm from the bottom of tank.

-

Roof primary drain check valve shall be provided.

-

Storage temperature is 40°C considering maximum recommended storage TVP for Atmospheric External Floating Roof Tanks.

The existing On-Spec Oil Tank has been designed taking into consideration, the following criteria: -

Total of 2 Tanks during EO phase.

-

No additional tanks under FFD.

-

Low pressure storage tank will be installed with design pressure of 1.0 barg.

-

API 620 will be applied.

-

Each tank has 10,000m3 nominal capacity.

-

Storage temperature is under 65°C.

-

Pressure relief device is set to the relieving pressure at 0.7 barg.

-

Emergency vent manway shall be provided for external fire case with 0.8 barg of set pressure.

-

Sample valve STRAHMAN type or equivalent shall be provided at 1500 mm from the bottom of tank.

-

Blanketing with LP Fuel Gas and out-breathing to LLP Flare will be provided.

The existing Off Spec/Slop Tank has been designed taking into consideration, the following criteria: Two Low pressure storage tanks will be installed with design pressure of 1.0 barg (during EO phase). -

API 620 will be applied.

-

Each tank has 4,600 m3 working capacity, 14 hours hold-up on one Crude Oil Train Capacity (50,000 BOPD).

-

Pressure relief device is set to the relieving pressure at 0.7 barg. TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

-

Emergency vent manway shall be provided for external fire case with 0.8 barg of set pressure.

-

Sample valve STRAHMAN type or equivalent shall be provided at 1500 mm from the bottom of tank.

-

Blanketing with LP Fuel Gas and out-breathing to LLP Flare will be provided.

The existing Export Oil Booster Pump has been designed taking into consideration, the following criteria: -

Four operating and one spare pump are provided (under EO).

-

The type of Pump is barrel vertical type.

-

Design capacity of each pump is 1,200 m3/h

-

Pumps shall be provided with their own dedicated minimum flow lines.

-

Pumps are electric motor driven.

The existing Export Oil Pump has been designed taking into consideration, the following criteria: -

Four operating and one spare pump are provided (under EO).

-

Pumps take suction from Export Oil Booster Pumps.

-

One pump shall be provided to deliver the stabilized crude to the pipeline for export to TUBA Tank Farm.

-

The crude shipping pump system shall be designed in conjunction with the crude oil pipeline to be installed and the maximum pressure drop at the terminal.

-

The maximum discharge pressure should not exceed the Maximum Allowable Operating Pressure (MAOP) of the crude oil pipeline under either normal operating or blocked-in conditions.

-

The pumps shall be equipped with minimum flow recycle streams.

-

Pumps are electric motor driven.

The existing Off Spec/Slop Oil Pump has been designed taking into consideration, the following criteria: -

One pump is installed per each Off Spec/Slop Tank, total two pumps (under EO).

-

Off Spec/Slop Oil Pump will be barrel vertical type.

-

Design capacity of each pump is 419 m3/h

-

Pumps shall be provided with their own dedicated minimum flow.

-

Pumps are electric motor driven.

-

Off Spec/Slop Oil is delivered by means of pumps to the suction of 1st Oil Heater to be reprocessed.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

The existing Storage Closed Drain Drum/Pump has been designed taking into consideration of the following criteria:

8.4.

-

One Storage Closed Drain Drum shall be provided to receive product from drain lines and will collect product from thermal expansion valves located in the storage area.

-

LP Fuel Gas is provided to avoid vacuum condition.

-

An underground horizontal drum will be installed.

-

Oil stored in the Closed Drain Drum will be transferred to the Off Spec/Slop Tanks via Closed Drain Drum Pump.

-

Design capacity of pump is 20 m3/h + MCF.

-

Pump is electric motor driven.

Battery Limit Battery limit conditions of process streams entering and leaving System 410 are reported in the following table: Temperature (°C)

Pressure (barg)

Fluid Identification Operating

Design

Operating

Design

40 - 65

90

5.2

16 (1)

40 - 75

90

5.2

16 (1)

Off Spec Oil from Closed Drainage Header to Off Spec / Slop Oil Tanks

90 max

110

4.5

Export Oil from Export Oil Pumps to Export Oil Fiscal Metering (System 468)

40-65

85

66

Off-Spec Oil from Off Spec / Slop Oil Pump to Crude Oil Trains

90 max

105

12

Stabilized Oil from Crude Oil Trains to Export Oil Storage Tanks Off Spec Oil from Crude Oil Trains to Off Spec / Slop Oil Tank

9.0

85

16.9 System 410 Battery Limit conditions

(1) Design pressure based on stabilized oil pump shut-off pressure.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

OIL TRAINS CLOSED DRAINAGE SYSTEM (UNIT 451) 8.5.

Process Description Closed Drainage System collects drained liquids from all hydrocarbon containing vessels, manifolds and equipment throughout the CPF. A dedicated 3 drainage systems have been provided during Early Oil Production Phase 1 & 2, while one additional drainage system (451-03-V-002 & 451-03-P-002) will newly be provided during Full Field Development Phase for the two new oil processing trains. -

22-451-00-V-001 (Inlet Closed Drain Drum)

-

22-451-01-V-002 (Oil Train Closed Drain Drum)

-

22-451-02-V-002 (Oil Train Closed Drain Drum)

-

22-451-03-V-002 (Oil Train Closed Drain Drum)

-

22-451-00-P-001 (Inlet Closed Drain Pump)

-

22-451-01-P-002 (Oil Train Closed Drain Pump)

-

22-451-02-P-002 (Oil Train Closed Drain Pump)

-

22-451-03-P-002 (Oil Train Closed Drain Pump)

Equipment and lines in inlet separation system including HP separator must be drainable to the Closed Drain Drum (22-451-00-V-001). All equipment and lines in Oil train No. 10 and 11 must be drainable to the new Closed Drain Drum (22-451-03-V-002), while the same in oil train #1, #2, #3 must be drainable to the existing Closed Drain Drum (22-451-01-V-002) and that in oil train #4, #5, #6, #7, #8, #9 must be drainable to the existing Closed Drain Drum (22-451-02-V-002). Unit 451 consists of an underground piping network and collection vessel to receive liquid drains. A sump pump is provided to send collected liquid to the off-spec / Slop Tank (22-410-00-TK-003 A/B) from which it can be returned to the process. The system will normally receive heavy hydrocarbon fluids, but may also receive small quantities of separated hydrocarbon condensate and water from vessels. A vacuum truck connection is provided for pumping rainwater and any hydrocarbon spillages out of the pit to the oily sewer. 8.6.

Unit Capacity Unit 451 Closed Drain Drum (22-451-03-V-002) shall be designed with a hold-up to accommodate the largest inventory contained in any equipment connected to the Closed Drain system that cannot be displaced by any other means to the Off spec / Slop Tank (22-410-00-TK-003 A/B) and hence, has to be sent via the closed drain header.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

8.7.

Basic Design Criteria The existing Inlet Closed Drain Drum has been designed taking into consideration of the following criteria: Closed Drain Drum is a horizontal drum -

The largest inventory to be drained from inlet separation system is the HP separator volume.

-

No credit is taken for pumping out from the closed drain vessel during draining.

-

Around 85% high high level (HHL) is specified to leave sufficient space for disengagement of any vapor flashed from the drained liquid and to reduce the risk of carry-over of liquids to the LLP Flare system.

-

The pressure is balanced to LLP flare header, a continuous flow of fuel gas (FG) ensures the absence of air, and avoids vacuum conditions during liquid pump out.

-

F.V. is not considered when steam out is carried out. F.V. will be prevented by opening vent nozzle and manway as per the maintenance procedure.

Oil Train Closed Drain Drum (451-03-V-002) in FFD phase is designed based upon the following criteria: Closed Drain Drum is a horizontal drum -

The largest inventory to be drained in Crude Oil Train is the MP separator volume.

-

No credit is taken for pumping out from the closed drain vessel during draining.

-

Around 85% high high level (HHL) is specified to leave sufficient space for disengagement of any vapor flashed from the drained liquid and to reduce the risk of carry-over of liquids to the LLP Flare system.

-

The pressure is balanced to LLP flare header, a continuous flow of fuel gas (FG) ensures the absence of air, and avoids vacuum conditions during liquid pump out.

-

F.V. is considered when steam out is carried out @ 1 barg (120 oC)

Oil Train Closed Drain Pump (451-03-P-002) is designed based upon the same design criteria as the existing oil train closed drain pumps (451-01/02-P-002) as follows: Sump pumps shall be designed to pump contents in each Closed Drain Drum to the Off Spec/Slop Tank (22-410-00-TK-003 A/B). -

Pump will operate in intermittent service.

-

Only one pump will be installed at each Closed Drain Drum.

-

Design flowrate shall be such that it lowers the closed drain drum contents from HHL to LLL, with no inflow to the drum, in 15 to 30 minutes.

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

8.8.

Battery Limit Inlet battery limit conditions will vary depending on which equipment or line of the crude oil train is drained. For operating conditions in the crude oil train refer to Heat and Material Balances. Battery Limit conditions of outlet streams from Unit 451 are reported in following table:

Temperature (°C) Fluid Drain to Off spec / Slop Tank (22-41000-TK-00 3 A/B)

From Inlet Closed Drain Drum (22-451-00-V-001) Oil Train Closed Drain Drum (22-451-01-V-002) (22-451-02-V-002) (22-451-03-V-002)

Pressure (barg)

Operating

Design

Operating

Design

34-60

85

4.5

9.0

90 (max.)

120

4.5

9.0

Unit 451 Battery Limit conditions

TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

9.

EXPORT OIL FISCAL METERING SYSTEM (UNIT 468) 9.1.

Process Description Export oil is measured by Export Oil Fiscal Metering before being routed to the export pipe line.

9.2.

Basic Design Criteria Since the existing Export Oil Fiscal Metering System has been designed with 3 * 50% meter runs for 400,000 BOPD + 15% overdesign, one additional meter run shall newly be added for 500,000 BOPD + 15% overdesign.

9.3.

Battery Limit Battery limit conditions of process streams entering and leaving System 468 are reported in the following table: Temperature (°C)

Pressure (barg)

Fluid Identification Operating

Design

Operating

Export Oil from Export Oil Pumps (22-410-00-P-002 A/B/C/D/E)

40-65

85

66

Export Oil to Pipeline

40-65

85

65

System 468 Battery Limit conditions

TOYO ENGINEERING CORPORATION

Design

85 85

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

10. OIL TRAINS CHEMICAL STORAGE AND INJECTION (UNIT 490) 10.1.

Process Description Refer to Drawing(s): 8015-0151-TOYO-22-490-PC-PF-00002 Under EO phase, unit 490 provides the facilities for the demulsifier, corrosion inhibitor and corrosion inhibitor (gas phase), necessary in the process units of the Mishrif CPF. Chemicals are injected into the fluid stream for enhanced system operation. Under FFD, one additional Demulsifier injection package (22-490-04-PK-001) is considered for injecting the demulsifier at inlet manifold system and 1st and 2nd stage desalters (of train 10 &11) in CPF. This will be done in order to mitigate potential emulsion in the equipment and piping.

10.2.

Unit Capacity Consumption of demulsifier has been determined based upon the chemical vendor information for the existing demulsifier injection packages (490-01/02/03-PK-001). A required chemical concentration of 20 ppm in total fluid for the inlet of HP Separator and each 5 ppm in total fluid for the inlet of 1st & 2nd stage desalters.

10.3.

Basic Design Criteria Demulsifier injection package is designed taking into consideration, the following criteria: The package comprises the storage tank and injection pumps with the relevant piping and instrument. -

Consumption of demulsifier is based on a required chemical concentration 20 ppm in total fluid for the inlet of HP Separator and each 5 ppm in total fluid for the inlet of 1st & 2nd Desalter.

-

The pump capacity is 1 x 100%.

-

Chemical storage capacity of at least 14 days is considered.

-

A portable unloading pump that can be used as a common spare for the existing EO phase injection package.

Existing corrosion inhibitor injection package for inlet crude oil distribution manifold and gas phase corrosion inhibitor injection phase for HP/MP & LP separators has been checked for adequacy considering FFD flow rates and were found to be adequate.

10.4.

Battery Limit Battery Limit conditions of in/out streams of Unit 490 are reported in following table: TOYO ENGINEERING CORPORATION

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Lukoil Mid-East Limited Doc. No. 8015-0151-TOYO-00-000-PC-BD-00002_02 WEST QURNA 2 – FULL FIELD DEVELOPMENT LUKOIL MID-EAST LIMITED

Temperature (°C) Operating Design

Fluid

Demulsifier

ATM

85

Pressure (barg) Operating Design 20.0 @ HP 16.0 @ HP Separator Separator /20.0@ 1st /15.0@ 1st stage desalter stage desalter /20.0@ 2nd /15.0@ 2nd stage desalter stage desalter

Unit 490 Battery Limit conditions

TOYO ENGINEERING CORPORATION

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