Naimat LPG Plant Revamp Project.pptx Description

Naimat LPG Plant Revamp Project. Intent of this project is to increase gas processing capacity and enhance LPG recovery of existing plant by adding new equipment.
The existing unit is capable of processing 60 MMSCFD gas at 60% LPG extraction efficiency. However, after the revamp project LPG plant will process 100 MMSCFD gas at 95% efficiency.
Current LPG plant is propane refrigeration based with JT valve arrangement. Revamped version will include Turbo Expander and propane based refrigeration system.
UEPL has carried out a preliminary FEED study the results of which are described here and will be used for the ITB. The Bidders are required to carry out their own study for the purpose of bidding.
Inlet Design Specifications:
Water Content: 7 lb/MMSCF
CO2: 3 – 5mol %
Flow: 100 MMSCFD�Pressure : 800 – 1000 psig
Temp : 80 – 130 degF

1. NAIMAT LPG UPGRADE PROJECT April, 2016 1

2. BACKGROUND 2 Intent of this project is to increase gas processing capacity and enhance LPG recovery of existing plant by adding new equipment. The existing unit is capable of processing 60 MMSCFD gas at 60% LPG extraction efficiency. However, after the revamp project LPG plant will process 100 MMSCFD gas at 95% efficiency. Current LPG plant is propane refrigeration based with JT valve arrangement. Revamped version will include Turbo Expander and propane based refrigeration system. UEPL has carried out a preliminary FEED study the results of which are described here and will be used for the ITB. The Bidders are required to carry out their own study for the purpose of bidding . Parameters Current Capacity Operating Capacity (Performance Test) Gas path 60 MMSCFD 100 MMSCFD LPG recovery 80 MTPD 208 MTPD* Propane recovery 60% 95% Butane recovery 60% 98.5% Sales Gas pressure 1200 psig 1200 psig Sales Gas Flowrate 45 MMSCFD 95.7 MMSCFD Heating value (min) 950 BTU/Scf 950 BTU/ Scf *LPG recovery 208 MTPD is based on 2.57 mol % C3, 1 mol % C4 in feed gas

3. LPG PLANT UPGRADE DESIGN BASIS 3 Gas Analysis for Revamp Case (Dated 01-Nov-2015 ) Feed Gas Composition Revamp Study Component Mole % Mole % Hydrogen Sulphide Carbon Dioxide < 3 2.76 Nitrogen 12 – 16 5.618 Methane 69 – 75 80.788 Ethane 8 – 9 6.69 Propane 2.5 - 3.5 2.57 i -Butane 0.4 - 0.6 0.382 n-Butane 0.7 - 0.9 0.647 i -Pentane 0.2 - 0.3 0.174 n-Pentane 0.2 – 0.3 0.152 Hexanes Plus 0.2 – 0.3 0.200 LPG Required Specification Vapor Pressure @ 100 psig Min Psig 70 Max Psig 159.5 Gross Heating Value Min BTU/ lb 18,000 95% Boiling point (14.7 psia ) Max O F 36 Pentane and Heavier contents Max Vol % 2 Specific Gravity Liquid (Water=1) Min 0.53 Max 0.57 Gas Flowrates in Individual Separators for Revamp Case Separator and flowing wells Gas rates V-8101 (RN,UMA,SLH, RHM-1X,Theb) 20 MMscfd V-8102 (KN, NAB, NB-2X) 7 MMscfd V-81006 (Naw-3,Rajani, Salamt ) 73 MMscfd Inlet Gas Flow Rate 100 MMscfd Inlet Design Specifications: Water Content: 7 lb /MMSCF CO2: 3 – 5mol % Flow: 100 MMSCFD Pressure : 800 – 1000 psig Temp : 80 – 130 deg F Note: Process upset conditions to be specified separately

4. EXISTING LPG PLANT PFD 4 P-8201 A/B Liquid to Crude Oil Stabilizer Liquid to De-Ethanizer Out Propane In Methanol In as Antifreeze MEG for moisture abs. J-T Valve Propane In Out Residue gas C1 MEG Recovery LCV LCV Propane In Propane Out De- Ethanizer D-8210 Cond. From Absorber V-8201 Hot Oil In Propane In Out C-8203 H-8203 Out PCV LCV Hot Oil In Out H-8204 Re-boiler To Flare P-8204 A/B CWS In CWR Out FEED GAS LCV LCV Gasoline Circulation Gas to Sales E-8205 E-8215 A - D Gas to Sales Gas Compressors NGLs To Crude Oil Stabilizer D-8201 Absorber Gasoline Tank T-8201 Liquid Scrub D-8206 Cold Sep V-8204 D-8211 De-Propanizer Liquid Scrub D-8204 C-8101 C-8102 C-8103 From C-8203 LPG Plant LP Comp Reflux Accumulator V-8205 E-8206 E-8207 E-8208 E-8209 LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 120 Tons LPG to Storage

5. Out Out Propane In J-T Valve EQUIPMENT REPLACEMENTS 5 P-8201 A/B Liquid to Crude Oil Stabilizer Liquid to De-Ethanizer Methanol In as Antifreeze MEG for moisture abs. Propane In Residue gas C1 MEG Recovery LCV LCV Propane In Propane Out De- Ethanizer D-8210 Cond. From Absorber V-8201 Hot Oil In Propane In Out C-8203 H-8203 Out PCV LCV Hot Oil In Out H-8204 Re-boiler To Flare P-8204 A/B CWS In CWR Out FEED GAS LCV LCV Gasoline Circulation Gas to Sales E-8205 E-8215 A - D Gas to Sales Gas Compressors NGLs To Crude Oil Stabilizer D-8201 Absorber Gasoline Tank T-8201 Liquid Scrub D-8206 Cold Sep V-8204 D-8211 De-Propanizer Liquid Scrub D-8204 C-8101 C-8102 C-8103 From C-8203 LPG Plant LP Comp Reflux Accumulator V-8205 E-8206 E-8207 E-8208 E-8209 LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 120 Tons LPG to Storage Equipment that need to be replaced

6. PROPOSED LPG PLANT UPGRADE SCHEME 6 New SOW To be Re-used PROPANE BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 50 Tons LPG BULLET 120 Tons LPG BULLET 120 Tons LPG BULLET 120 Tons Molecular Sieve From Naimat Gas Complex Mercury Guard Bed Feed Gas Cold Box 7 Pass Heat Exchanger Cold Separator Turbo Expander and Re compressor De- Ethanizer D-8210 H-8203 To Flare E-8215 A - D D-8211 De- Propanizer Reflux Accumulator V-8205 H-8204 NGLs To Crude Oil Stabilizer LPG to Storage Reflux accumulator De- Ethanizer De- Ethanizer Cond C-8101 C-8102 C-8103 C-8203 New Comp De- Ethanize OVH Comp Through inlet Cold box New Comp On Wellhead Compression Service Gas to Ph-1 and 2 Sales Gas To POD LPG BULLET 120 Tons P-8204 A/B Cryogenic Oil Absorption Column Refrigerant from Refrigeration Unit Refrigerant to Refrigeration Unit To Cold Box Lean Oil Charge pump J-T Valve Installation of JT valve on turbo expander by pass to ensure that when turbo expander is offline (for CM/PM), LPG plant will run through JT valve New Comp New Comp New Comp

7. OFFSITE & UTILITIES UPGRADE/EXTENSION POWER GENERATION & CONTROL SYSTEM 480 volts / 60 Hz HOT OIL SYSTEM EXTENSION FIRE WATER LOOP EXTENSION FUEL GAS SYSTEM EXTENSION DRAIN SYSTEM UPGRADE 7 WARM & COLD FLARE HEADER EXTENSION LPG STORAGE UPGRADE INSTRUMENT AIR SYSTEM UPGRADE UPGRADE EXTENSION LEGENDS: PROPANE REFRIGERATION SYSTEM CHILLED WATER SYSTEM

8. 8 LPG PLANT UPGRADE EQUIPMENT LIST New Equipment List S.No Equipment Qty Equipment Sizes 1 Molecular Sieve 1 Handling capacity ~ 100 MMscfd with 20% design margin 2 Mercury Guard Bed 1 Handling capacity ~ 100 MMscfd design margin 3 Feed Gas Cold Box 1 Multi pass exchanger 27.3 MMBtu / hr design duty with 7 passes 4 Cold Separator 1 78 inch ID X 36ft-9 inch S/S 5 Cryogenic Lean oil Absorber 1 72 inch ID X 75ft S/S 6 Cryogenic Lean Oil Charge Pump 2 2 X 120 USGPM @ 120 psig 7 De- Ethanizer Condenser 1 Multi pass exchanger 4.5 MMBtu / hr design duty with 2 passes 8 De- Ethanizer Reflux Accumulator 1 54 inch ID X 18ft S/S 9 Turbo Expander with Re-compressor 1 915 hp 10 Booster Gas compressor 3 3 X 1500 hp 11 Sales Gas Compressor 2 2 X 1500 hp 12 LPG storage Bullets 3 3 X 120 Mton 13 LPG Loading Pump and Loading meter 1 01 each 14 IA Compressor 1 01 Skid

9. 9 LPG PLANT REDUNDANT EQUIPMENT LIST Redundant Equipment List S.No Equipment Tag Service Equipment Sizes 1 E-8206 Gas / Gas Exchanger 3.27 MMBtu / hr 2 E-8207 High Level Gas Chiller 3.26 MMBtu / hr 3 E-8208 Gas / Gas Exchanger 3.46 MMBtu / hr 4 E-8209 Low Level gas Chiller 4.47 MMBtu / hr 5 E-8210 Refrigeration sub cooler 1.6 MMBtu / hr 6 E-8212 Residue Gas / Refrigeration Exchanger 1.72 MMBtu / hr 7 D-8201 Lean oil Absorber Column 42 inch ID X 60 ft S/S 8 P-8201A/B Condensate Injection Pump 77 USGPM (60 hp ) 9 E-8201 Condensate Coolers ----- 10 T-8201 Lean oil Surge Tank ------ 11 D-8206 Condensate Contactor OVH Scrubber 48 inch OD X 6ft S/S 12 V-8204 Cold Separator 60 inch ID X 32 ft S/S Notes: E-8210 and E-8212 will be replaced with E-8206 and E-8207 (redundant exchangers after revamp project)

10. 10 SALES GAS COMPRESSOR New Equipment New Bullets Existing LPG Plant Plant Gate NAIMAT PLOT PLAN

11. CONTRACTOR ORGANIZATION 11

12. TIMELINE 12

13. Compliance / Deviation list / Assumptions Performance Guarantee Re-validated Basic Engg Study / Simulation Model / PFDs & PIDs by Contractor Schedule / Acceptance of UEP Schedule & Milestone LDs Organogram (Company & Project Specific) / Min. Organization Format Key Engineering & Project Team Resume Highlighting LPG Plant Design Experience. Incase engineering is sub-contracted complete information in accordance with the ITB as for Primary bidder shall be required Subcontractor/ Vendors / Manufacturers Details Reference List of Similar Projects Executed List of On-going & Future Commitments Contractor Profile Resource Deployment Plan (E,P,C) Applicable Certification & policies Project Execution Plan Commissioning Organization & Plan Training Plan of O&M Personnel Filled in Bid Format / BOQ Project Quality Plan Engineering Quality Assurance Plan QA/QC Plan for Manufacturing Contractors Procurement Management Plan / Job award procedure Compliance to Preferred Vendors List BID DELIVERABLES 13

14. ENGINEERING ASSURANCE 14 1) RE-VALIDATION OF BASIC DESIGN 2) PROCESS PACKAGE FINALIZATION 3 ) DETAILING EDR- I EDR-II (Technical Review of Eqpt ./ Finalization Process Model Endorsement & Finalization of PFD UEP Review UEP Review HAZOP Close Out CR* CR* CR* Complete Process Package Approved by UEP Engg Authority UEP Review UEP Review/ Approval *CR: Constructability Review

15. PROCUREMENT Preferred vendor list for procurement of critical equipment Information of OEM vendors of subcomponents to be provided Procurement Phases Long Lead Items Level-I BOM Level-II BOM Intermediate inspection, expediting & quality assurance Commissioning spares & assistance Identification of safety critical & production critical spares Two years operating spares including spare expander/compressor shaft & turbine Ex works delivery CONTROLS R eview of Contractor’s procurement procedures Share Copy of POs Procurement status / tracking sheet including payment disbursement / delivery dates Third party inspection & expediting as per ITPs FAT 15

16. MATERIAL FROM EX-WORKS TO PROJECT SITE Shipment, Customs clearance & inland logistics Packaging as per UEPL guideline (Sea worthy packaging) Complete insurance coverage (Marine/ Inland/ Air) Location of procurements to be identified Delivery / Shipments as per agreed schedule Journey management plan CONTROLS Late delivery penalty / LD Shipping documents (CI, PL, BL) Detailed package list for individual equipment 3 rd party survey report for each shipment to be shared Tracking & sharing of logistics status 16 LOGISTICS

17. MATERIALS MANAGEMENT Laydown / Staging area Unloading, De-stuffing and De-crating Materials inspection Use of Material Management Systems to monitor receipts, issuance and returns CONTROL Periodic audits of material issuance, receipt and returns As built & material reconciliation Periodic update required vs receipt material Mechanism for using alternate / missing material 17

18. CONSTRUCTION Contracting Strategy, Construction E xecution Plan & Emergency Response Plan Construction & QA/QC organization Camp site, construction and storage yard development Hook-up & Dismantling Strategy SIMOPs during plant operation Provision for night shifts Fire Fighting Setup & Crew Composition All UG works to be completed on priority Process for handling t echnical queries / design discrepancies Material reconciliation Submission of as-built drawings and dossiers CONTROLS PHSER - Relevant legal approvals in place Technical evaluation of Bids ( Civil, Mech & I&E) Equipment , Manpower & Tools/ Tackles certification for hazardous area, Lifting Plan COW & Permit to Work system shall be implemented Full time operation and HSE representative Change control mechanism Agreed Progress Monitoring & Controlling System, Rigorous Monitoring of Test Pack Closure Quality Inspection Plan 18

19. COMMISSIONING UEP Commissioning team well before commissioning Deployment of commissioning experts from OEM & Engineering consultant Training for O&M personnel by OEM Commissioning plan, SD/ startup procedures, SOPs / ERPs shall be developed Arrangement of equipment, spares (commissioning & 2 year spares), tools and consumables for plant commissioning Performance test of 72 hrs. after 48hrs of smooth operation CONTROL Presence of OEM & Engineering Consultant during commissioning Fire fighting setup & Emergency Response equipment to be in place PSSR 19

20. 20 BACKUP SLIDES