Students: ID# Mugtaba Khalid Younis 200440288 Abdullah Saleh 200400484

1. UAE University Graduation Project Unit Petroleum Engineering Department GPI Fall 2010 Design of Water And/orGas Injection Plant • Examination Committee: Prof. Kama Moustafa (College) Dr. HazimAlAttar (Dept.) Prof. AbdulrazaqZekri (Dept.) Advisor: Dr. Mohamed A. Al Nakoua Students: ID# Mugtaba Khalid Younis 200440288 Abdullah Saleh 200400484

2. Outlines Introduction Objective Project Management Project Deliverables Literature Review Applications in UAE Possible Alternatives and Selection Preliminary Design and Material Balance HYSYS software Cost Estimation and HAZOP Study Safety and Environmental Consideration Conclusions

3. Introduction • Problem Review: • Reservoir pressure declines with time. • Part of oil still not recovered. • External Energy needed ( Mainly water or gas Injection ).

4. Objective • Design a complete Water and/or Gas injection plant. • Processing steps: • Separation • Treatment and Injection of Gas/Water • Design, Sizing plant units • Safety, Environmental and Economical Considerations

5. Project Management • Gantt Chart

6. Project Deliverables • Identify the quality and quantity of the gases/water which available for processing/treatment and injection. • Select the suitable gas/water and specify it’s conditions and composition. • Optimize the sequence of the plant’s major units • Perform material balance on each unit. • Design the plant units based on suitable location. • Estimate the cost of the injection plant. • Consider environmental, safety and company policy in plant design.

7. Literature Review • Injection Well ? • Fluids are injected rather than produced, primary objective is to maintain reservoir pressure, and common types of injection gas and water. • Secondary Recovery • Method that used to either: Enhance the well productivity and/or Maintain reservoir pressure. • Produces about 30% to 50% of the original oil in place.

8. Literature Review • Separators • Remove impurities and separate the different fluids from each other. • Most properties of the separator: • primary phase separation • Refine the primary separation by removing most of the entrained gas from liquid mist from the gas • Discharge the separated gas and liquid from separator and insure that no re entrainment of one into other takes place

9. Applications in UAE • Zakum Development Company (ZADCO): • Pumped up the sea water by 5 winning pumps. • Filtration by sand filters: solids 0.2 ppm. • Evacuate oxygen by Vacuum Towers. • Booster pumps : give suction of 300 psi. • High Pressure Pumps (HPP) :(∆P) discharge = 3000 psi.

10. Possible Alternatives • Types of Separators

11. Possible Alternatives • Types of Separators

12. Possible Alternatives • Types of Pumps • Positive displacement pumps • Centrifugal pump

13. Possible Alternatives • Types of Compressors • Centrifugal Compressors • Reciprocating Compressors

14. Possible Alternatives • Gas/Liquid Separation: Number of Stages • Obtain maximum recovery of liquid hydrocarbons. • Increase API gravity

15. Selection • The components of the design: • Three-phase horizontal separator. • Two stage separation. • Associated gas and water from production well to be treated and re-injected. • Two stage pumping. • Two stage Compression.

16. Preliminary Design

17. Preliminary Design • Gas Treatment: • Distillation column: Obtain CH4. • Gas Sweetening: Remove the sour gases such us H2S and CO2 by Amine Solution. • Gas Dehydration: Remove water from the gas by Glycol.

18. Preliminary Design • Dehydrate

19. Preliminary Design • Water Treatment: • Filtration: solids within 40 micron rejected • Chemical Treatment: Corrosion Inhibitor

20. Material Balance Input + Generation - output - Consumption = Accumulation Since, Steady-State: No consumption No Generation No Accumulation So, Input = Output

21. Material Balance ρ= m / v m= ρ * v • To convert from bbl to cu.ft, we used the conversion 1 bbl = 5.615 (cu.ft.) ρo = 54.66 Ib/cu.ft V = 70614.82 bbl/d * 5.615 cu.ft/bbl = 396.5*10^3 cu.ft/d m = 396.5*10^3cu.ft/d * 54.66 Ib/cu.ft = 21.67*10^6 Ib/d

22. Material Balance • Number of moles entering 1st separator = m / Σ(Mw* X)i = 21.67*106 (Ib/d) / 63.3 (Ib /Ib mole) =342.38*10^3 Ib mole/d

23. Material Balance • Around 1st separator (@ P=1000 psi, T= 100 °F): Vapor fraction = 0.328 • Num. of mole in * Vapor fraction = Num. of moles of Gas

24. Material Balance • Around 2nd separator (@ P=14.7 psi, T= 60 °F): Vapor fraction = 0.819 • Num. of mole in * Vapor fraction = Num. of moles of Gas

25. HYSYS software

26. HYSYS software

27. Detailed Design • It is important in designing the separator to consider these factors: • Gas and Liquid flow rate ( oil & water ). • Types of the separator (2 or 3 phase). • Specific gravity of oil, water and gas. • The presence of foaming tendencies. • The presence of solid impurities (sand or paraffin). • Required retention time of the fluids within the separators. • Temperature & pressure at which separator will operate and design pressure of vessel.

28. Separator Design First : Procedure of sizing three-phase horizontal separator Gas Capacity: Gas capacity constrains is given by:

29. Separator Design Retention Time:

30. Separator Design Settling Equation:

31. Separator Design

32. Separator Design Second : Procedure of sizing three-phase vertical separator • Calculate minimum diameter from requirement for water droplets to fall through oil layer. (Use 500-micron droplets ) ; • Calculate minimum diameter from requirement for oil droplets to fall through gas. (Use 100-micron droplets )

33. Separator Design 3. Choose the larger of the two as dmin. 4. Select (tr)0 and (tr)w, and solve for h0 + hw for various d. • Estimate seam-to-seam length using the larger value. 6. Select a size of reasonable diameter and length. Slenderness ratios (12 Lss/d) on the order of 3 to 5 are common.

34. Separator Design First Scenario: Horizontal Separator Vertical Separator

35. Separator Design Second Scenario: Horizontal Separator Vertical Separator

36. Dehydration Column Design Sizing the Dehydration Column - Optimize Pressure and TEG circulation rate: - 1st Step: Obtain TEG concentration

37. Dehydration Column Design • 2nd Step: Calculate Water Removal Efficiency for different pressures.

38. Dehydration Column Design • 3rd Step: Obtain TEG circulation rate for each pressure

39. Dehydration Column Design • Results:

40. Pump and Compressor Design • Using the HYSIS software, the horse power required for pump and compressor was obtained:

41. Cost Estimation • Important step in order to figure out if the project is profitable or not.

42. Cost Estimation • Results:

43. HAZOP Study • Analysis method to identify and minimize the hazards of a process and improve its effectiveness. • Aim of the HAZOP study is to minimize or avoid the risk and hazard that may happen in the process. • Some HAZOP study done for some units: • Dehydration Column • Separator • Pump

44. Safety Considerations • Personal Protection Equipment • Site Preparation • Gas Detection Equipment • Day light and high visibility work

45. Environmental Considerations • Engineering responsibility for the environment is important. • Legal standards should met . • Several types of wastes affect the environment harmfully {(CO2) , (H2S)}.

46. Conclusions • Summary: • Objective : Design a water and/or gas injection plant( Separators, Dehydration Column, Pump and Compressors) • Safety and Environmental aspects were considered. • Cost estimation and HAZOP study were done. • Field data provided by ADCO.

47. Conclusions • PVTi software : Composition analysis & Material balance. • Powerful HYSYS software for pump and compressor design.

48. Conclusions • Problems Faced: • Field data : took time. • HYSYS : Used for the first time.

49. Conclusions • Skills Learnt: • Improved our communication skills. • Manage time and tasks : 'Gantt chart‘. • HYSYS industrial software : great role in our project. • Preparing professional reports and presentations.

50. Thank You… ANY QUESTIONS