TDE Corporate Portfolio Rev 1.0 (10-May-09) Turn Key Projects.pdf · Thermo Design was awarded a...

Turnkey Projects

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T U R N K E Y P R O J E C T S

Z A I K I N S K O Y E P R O C E S S I N G P L A N T

O R E N B U R G N E F T O F R U S S I A

Tulipan, Russia (Southwest Russia)

P R O J E C T S U M M A R Y

Thermo Design was awarded a contract with OrenburgNeft (currently a division of TNK – Turkmen Neft Company & BP – British Petroleum) to supply on a Turnkey basis a Gas Processing Plant to process a maximum of 260,000 Nm3/hr (220 MMSCFD) of natural gas and to complete the design services for the future phases of the plant expansion including Oil Stabilization and a Mini Refinery.

The contract included the following Thermo Design supplied equipment and services:

Supply of modular gas processing plant designed and manufactured as twin parallel processing trains.

Construction supervision by Canadian construction specialists for installation of the gas plant. Plant construction utilizing OrenburgNeft equipment and tradesmen.

Commissioning and start up management / responsibility.

Training of OrenburgNeft specialists and operators.

Run test of plant, punch list resolution and sign over to OrenburgNeft.

Registration of plant and equipment with Russian Authorities and Standards Agencies.

Engineering Study (feed engineering) for Phase 2 of the complex that included additional processing of liquids products as well as oil & condensate stabilization, product rail loading facilities and LPG bottling facility.

Engineering Study (feed engineering) for Phase 3 of the complex – A Mini Refinery processing 500,000 tonnes per year of stabilized crude into gasoline, motor distillate and residue fuel oil.

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P R O J E C T E Q U I P M E N T S U M M A R Y

Inlet Gas Handling & Compression Gas Flow Rate: 260,0000 Standard Cubic Meter / hour (MMSCM/hr)

at58 Barg

(220 MMSCFD at 830 Psig)

Process Facilities: Inlet Slug Catchers, Inlet Separators, Inlet Filter Coalescers, Inlet Metering and Emergency flare control valves.

Gas Compressors: Two @ 50% capacity

Gas Compressor Type: Dresser Rand CBF-742 Centrifugal

Compressor Ancillaries: Lube oil console with SS piping, pumps, filters, & degassing tank. Seal oil system w/ seal oil tank, DR Cone Seals. Compressor after coolers consisting of 6 fans each train.

Compressor Driver HP: 12600 HP (nominal) (9396 kW)

Compressor Driver Type: Solar Mars 90 Gas Turbine

Turbine Ancillaries: Lube oil pump with DC back up, lube oil filtration, lube oil vent separator. Fuel gas treatment including filtration and heating. Gas starter. Inlet filter, heat exchanger, silencer & ducting Exhaust silencer & ducting. Turbine & compressor housed in heated building with overhead crane.

Gas Dehydration Dehydration Technology: Drizo

Gas Flowrate: 260,000 MMSCM/hr at 58 Barg (220 MMSCFD at 830 Psig)

Outlet Gas Water Dewpoint: -62° C at 22 Barg(-80° F at 310 Psig)

Lean Glycol: 99.99 wt% TEG

Glycol Contactor Type: Tower with Structured Packing

Number of Glycol Contactors: Two @ 50% Capacity

Lean Glycol Flowrate: 2 x 3.5 m3/hr (15 USGPM)

Glycol Stripping: Superheated recirculated solvent

Glycol Reboiler Duty: 2 x 293 kW (1.0 MMBTU/hr) (2 @ 50%)

Glycol Reboiler Type: TEMA BKU with Still & Stripping Column Steam Heated.

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Gas Chilling & LPG Recovery Gas Chilling Process per train: Two Gas / Gas NEN heat exchangers operating in

series with Gas / Chilled liquid BEM heat exchanger,evaporative chiller & horizontal low temperature separator.

Gas Chilling Temperature: -37 °C (-35 °F)

Gas Chillers: TEMA R NKN 2032 kW (6.7 MMBTU/hr)

Gas / Gas Exchangers: TEMA R NEN 4225 kW (14.4 MMBTU/hr)

Gas / Liquid Exchanger: TEMA R BEM 2418 kW (8.25 MMBTU/hr)

Refrigerant:: Propane evaporating at -40 °C (–40 °F)

Refrigerant Propane Process: Centrifugal compression, high pressure and low pressure economizers, refrigerant accumulator, filter drier, air cooled condensers and shell / tube evaporative chillers.

Propane Condenser Duty: Two @ 6740 kW (23 MMBTU/hr) air coolers consisting of 6 bays with 12 fans for each train.

Refrigerant Compressors: Two @ 50% Capacity / One common spare

Refrigerant Compressor Type: York M538A Centrifugal

Refrigerant Flow: 1203 kg/min (158,760 lb/hr) each Compressor Train.

Compressor Ancillaries: Propane cooled lube oil heat exchanger.

Refrigerant Compressor Driver: Solar Centaur 40 Gas Turbine 4700 HP (3500kW)nominal rating.

Turbine Ancillaries: Lube oil pump, lube oil filtration, lube oil vent separator.Fuel gas treatment including filtration and heating. Gas starter. Inlet filter, heat exchanger, silencer & ducting Exhaust silencer & ducting. Turbine & compressor housed in heated building with overhead crane.

LPG Fractionation (phase 1): Deethanizer tower w/ 30 valve trays 2428 kW BKU (8.3 MMBTU/hr) steam reboiler 2015 kW (6.9 MMBTU/hr) Brazed Aluminum core in kettle Reflux Condenser Reflux accumulator & Teikoku seal less reflux pumps.

Deethanizer Overheads Comp: (2) Thermo Design packaged Dresser Rand 9” 2HSE-2 Valve in Piston reciprocating compressors driven by 500 HP electric motors.

LPG Fractionation (phase 2): Additional deethanizer, debutanizer and depropanizer towers.

Propane Compression & Storage Systems Nominal Capacity: 17 SCFM

Two Single Stage, Oil Free, Air Cooled Reciprocating Compressors.

Auxiliary Equipment: Two 7, 800 Gallon Propane Storage Bullets Automated Sprinkler Firefighting System.

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Steam, Heat Medium & Water Systems High Pressure Steam: Two Watertube Boilers 100 kg/min

(13,200 lb/hr) Capacity per Unit 32 Barg @ 238 °C (460 Psig @ 460 °F)

Auxiliary Equipment per Boiler: Steam Drums, Water Drum, Tube Sections, Burner and Forced Air Blower, Fuel Gas Recirculation, Gas Ducts,Exhaust Stack, Blower Separator.

Low Pressure Steam: Two ERI WHRU's on Gas Tubines 185 kg/min (24,400 lb/hr) Capacity per Unit 13 Barg @188°C (175 Psig @ 370°F) Supply / 93 °C (200 °F) Return.

Auxiliary Equipment per WHRU: Economizer, Steam Drum, Blowdown Separator, Water Drum, Mud Drum Heater, Gas Ducting and Exhaust Stacks.

Heat Medium: 63 m3/hr 60% Weight Glycol @ 116°C (840 USGPM @ 240°F) Expansion Drum, EG/Water Exchanger, Circulation Pumps, Drain Tank, Drain Tank Sump Pump.

Water Systems: 63 m3/hr HVAC Water @ 66°C (275 USGPM @ 150°F);20 m3/hr Domestic Water Suppy @ 55°C (88 USGPM @ 130°F) Condensate Recovery & Storage

Water Treatment Systems: Boiler Feedwater Dearation Treatment for Scale/Corrosion and Oxygen Removal 14 m3/hr (60 USGPM); Boiler Feedwater Supply Treatment Using Carbon Filtration & Reverse Osmosis.

Flare & Drainage Systems Flare Type: Steam Assisted

Flare Capacity: 1887 kg/min (249,000 lb/hr) (110% of each Gas Plant Capacity)

Flare Design Criteria: Stack Velocity < 0.5 Mach Ground Level Radiation Level < 9.4 kW/m2 Smokeless Combustion of Full Gas Rate

Auxiliary Flare Equipment: Condensate Separation and Pumpout Three Pilot Burners with Electronic Ignition and Automatic Re-Light.

Plant Drainage Systems: Full Plant Flare and Process Drainage Requirements.

Plant Drainage Equipment:: Refrigeration, Gas Chilling & TEG Unit Flare Knockout Drums & Liquid Sump Pumps.

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Instrument Air & Nitrogen Generation Instrument Air Compressor Type: Oil Injected Rotary Compressors

Instrument Air Capacity: 312 SCMH @ 6 Barg & -60°C (11,000 SCFH @ 80 Psig & -75°F)

Compressor Operation: Two @ 100% Capacity

Auxiliary Equipment: Air Compressor Afterfilter Instrument Air & Utility Air Receivers

Nitrogen Generation Type: Permeable Membrane Unit

Low Pressure Nitrogen Product: 147 SCMH @ 10 Barg & > 97.5% N2 (5190 SCFH @ 145 Psig & > 97.5% N2)

High Pressure Nitrogen Product: 71 SCMH @ 75 Barg & >99.5% N2 (2475 SCFH @ 1,080 Psig & >99.5% N2)

Auxiliary Equipment: Oil Injected Rotary Feed Air Compressor, Feed Air Reservoir, Nitrogen Compressor Feed Reservoir, Firefighting & Utility Nitrogen Receivers.

Electric Power Generation Nominal Capacity: 10 MegaWatts (13,400 HP)

Generation Type: Two Solar Taurus 60 Gas Turbines with Ideal Electric Generators

Voltage: 6000 Volts

Steam Generators: ERI Waste Heat Recovery

Turbine Ancillaries: Lube oil pump, lube oil filtration, lube oil vent separator. Fuel gas treatment including filtration and heating. Gas starter. Inlet filter, heat exchanger, silencer & ducting Exhaust silencer & ducting Turbine & Generator housed in heated building with overhead crane.

Power Equipment: 6000 Volts and 660 Volts switch gear Step down transformers Emergency diesel generator

Control Systems I/O Points Approximately 3,000

Process Control Functions: Bailey INFI90 Distributed Control System (DCS) Three Operator Workstations in Russian Language Display One Engineering Console Two Report Printers & Two Alarm Printers

ESD Functions: Allen Bradley PLC5/60 with Remote I/O and GPI Communications to Bailey System

Power Distribution: 2 Citect Operator Interfaces with Power Distribution and MCC Status Indication in Russian Language Display

Fire & ESD Panels: 2 Siemens OP27 Color Panels for plant wide alarm indication functions in Russian Language Display

Turbine Control: Solar Turbotronics Control System with Allen Bradley PLC’s integrated into plant network

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Turbo Expander Plant

S T A T E C O N C E R N T U R K M E N G A S

NAIP Field, Turkmenistan (East Turkmenistan, Desert Location)


Thermo Design was awarded a contract, in December 2000, to supply LPG Recovery Plant with a nominal inlet gas flow of 9,000,000 m

3/day @ 40 Barg and 40

oC (320 MMSCFD @ 580 psi & 104°F).

The Plant consists of two (2) identical parallel trains with 4,500,000 m3/day capacity each, built and

delivered on a “turn-key” project basis. The project was completed in March 2003.

Thermo Design was awarded with a second contract, in July 2003, to expand the original Plant by addition of a 3

rd Train with the same capacity of 4,500,000 m

3/day. The Plant capacity was increased to process in

total 13,500,000 m3/day (480 MMSCFD) of gas and to recover 500 Tonnes/day (550 Tons/day) of LPG

and 300 Tonnes/day (330 Tons/day) of C5+ product. The project was completed in 2005.


Detailed Design (process, mechanical, electrical, instrumentation and control) and fabrication of the LPG Recovery Plant.

Registration of plant and equipment with Turkmenistan Authorities and Standards Agencies.

Shop testing of all equipment and system prior to shipping.

Supply of spare parts for commissioning, startup and 2-year of operation.

Supply of plant chemicals, lubricants and fire fighting equipment.

Site civil works and field assembly of the modular Thermo Design supplied equipment.

Responsibility for commissioning, startup and operational performance test.

Personnel training for processes and operation with emphasis on automated control system with local and remote monitoring stations.

Transportation to site.


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P L A N T E Q U I P M E N T S U M M A R Y

NOTE: The plant consists of three processing trains and equipment descriptions shown are per train.

Inlet Gas Handling

Gas Flowrate: 4,500,000 m3/day @ 40 Barg and 40°C (160 MMSCFD

@ 580 Psig and 104°F)

Process Facilities: 3-Phase Inlet Separator, 2 x 100% Inlet Filter Coalescers.

Gas Dehydration

Dehydration Technology: Mole Sieve Dehydration using Atofina: Siliporte PSF 316/330 SGD

Gas Flowrate: 4,500,000 m3/day @ 40 Barg and 40°C(160 MMSCFD @ 580 Psig and 104°F)

Outlet Gas Water Dewpoint: -100°C (-148°F)

Process Facilities: Three Mole Sieve Contactors @ 50% Capacity. (Two in drying and one in regeneration mode) and Dry Gas After Filter.

Gas Chilling & Turboexpansion

Pre-Gas Chillers: Brazed Aluminum Fin/Plate Heat Exchanger with three (3) services integrated in one unit, 12,171 kW (41.5 MMBTU/hr) total duty

Low Temperature Separator: 37 Barg @ -70°C (537 Psig @ -94°F)

Turbo Expander: Mafi Trench EC/Frame 3.75; Operating BHP: 1625 kW (2180 HP) for Expander, 1609 kW (2160 HP) for Compressor; Operating RPM: 12,300 – 13,700

Auxiliary Equipment: Lube Oil Circulation System, Seal Gas System

Stabilization & NGL Fractionation

Deethanizer Fractionation: Full SS Deethanizer Tower with 27 Valve Trays 1087 kW (3.7 MMBTU/hr) + 25% Reboiler.

Condensate Stabilization: Stabilizer Tower: 25 mm (1”) 304SS Pall Rings; 316 kW (1.08 MMBTU/hr) + 20% Reboiler; 154 kW (0.53 MMBTU/hr) + 10% Condensate Cooler (S&T) and 2x100% DC4 Condensate Feed Pumps.

Debutanizer Fractionation: Debutanizer Tower with 24 Valve Trays, 1798 kW (6.1 MMBTU/hr) + 10% Reboiler; 723 kW (2.5 MMBTU/hr) + 10% C5+ Product Cooler (Air Cooled Heat Exchanger); 1485 kW (5.1 MMBTU/hr) + 10% Overhead Condenser (Air Cooled Heat Exchanger); Reflux Accumulator & 2x100% Reflux Pumps

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Regeneration Gas System

Regen Gas Compressor: Sundyne Centrifugal Gas Compressor 33,000 m3/hr (1,165,384 ft3/hr)

Regen Gas Heater: 4000 kW (13.5 MMBTU/hr) Direct Fired Cabin Type Heater

Regen Gas Cooler: 3730 kW (12.7 MMBTU/hr) Air Cooled Hex

Regen Gas Dehydration: Glycol Contactor (Structured Packing), 182 kW (0.62 MMBTU/hr) Glycol Regenerator, Gas/Glycol Hex, Charcoal Filter, Particle Filter, 2x100% Glycol Pumps, Glycol/Glycol Hex and Regeneration Gas Air Cooled Heat Exchanger.

Auxiliary Equipment: Regen Gas Filter Coalescer & Separator

Utilities

Heat Medium System: 86 m3/hr @ 260°C (380 USGPM @ 500°F) Heat Medium Oil Circulation, 4250 kW (14.5 MMBTU/hr) Direct Fired Cabin Type Heat Medium Heater, Expansion Tank & 2x100% Heat Medium pumps

Instrument Air System: 66 m3/hr @ 8 Barg (2330 SCFH @ 116 PSIG) Instrument Air Flow Capacity, 2x100% Atlas Copco air compressors, I/A Pre-Filter, Dryer, After-Filter & Air Receiver

Methanol Injection: Methanol Storage Tank and 2x100% Methanol Injection Pumps

Fuel Gas: Fuel Gas Separator

Control Systems

I/O Points Approximately 2,000

Human Machine Interface: HMI system consists of two IBM workstations, a Report Printer and an Alarm printer. HMI displays both in English and Russian. One station is a HMI server that scans all the IO from the PLC and logs the data to an archive. The other computer is both a HMI client and an engineering workstation for programming both the HMI and PLC systems.

Process Control Functions: One Programmable Logic Controller System (Siemens CPU316-2 DP processor) connected via Profibus to a series of ABB Remote IO panels. All field wiring is terminated in the remote IO panels and thereby scanned and accessed by the PLC.

Flow Calculations: One Programmable Logic Controller System (Siemens CPU315-2 DP processor) receives raw flow data from the Process PLC and returns corrected flow rates as per AGA 3 specifications.

ESD Functions: Hard Wired Relay Based ESD system, The HMI can be displayed in both English and Russian. ESD system will override the PLC system if alarms go off.

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T U R B O E X P A N D E R L P G R E C O V E R Y P L A N T

I R A N I A N O F F S H O R E O I L C O M P A N Y

Kharg Island, Iran


Thermo Design was awarded a contract, in September, 2007 to supply two trains of NGL Recovery with a nominal inlet gas flow of 7,561,000 Sm3/day @ 61 Barg and 42ºC (267 MMSCFD @ 878 psig and 107°F).

The contract includes the following Thermo Design supplied equipment and services:



Transportation to Port.



Personnel training for processes and operation

Registration of plant and equipment with Iranian Authorities and Standards Agencies.

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NGL Recovery & Propane Refrigeration

2 x Gas Chillers: Residue Gas Exchangers, 7,377 kW (25.2 MMBTU/hr) total duty

Warm Inlet Chillers 4,576 kW (15.6 MMBTU/hr) total duty

Cold Inlet Chillers, 5,700 kW (19.4 MMBTU/hr) total duty

2 x Low Temperature Separators: Inlet Separator, 74 Barg @ -46°C (1073 Psig @ -51°F)

Warm Separaotors, 74 Barg @ -80°C (1073 Psig @ -112°F)

Cold Separators, 28 Barg @ -101°C (406 Psig @ -150°F)

2 x Propane Compressor Siemens; Required power 9,981 kW c/w Propane Refrigeration Condensers, Propane Refrigeration Economizers, Propane Compressor LLP Suction Drums, Propane Compressor LP Suction Drums, Propane Compressor MP Suction Drums, Propane Compressor HP Suction Drums, Propane Refrigeration Accumulator, Recovered Propane Storage Drum, Recovered Propane Pump, Propane Refrigeration Drain Pump

2 x Warm Expander/Compressor Package: Cryostar Required Power 1550kW c/w Residue Gas Compressor AfterCooler

2 x Cold Expander/Compressor Package: Cryostar Required Power 1522kW c/w Residue Gas Compressor AfterCooler

2 x Auxiliary Equipment: Lube Oil Circulation System, Seal Gas System

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NGL Fractionation & Stabilization

2 x Demethanizer Fractionation: Tower 3,000/2,100mm ID x 5,610/20,350mm s/s;Demethanizer reboiler 3,323 kW (11.3 MMBtu/hr); Demethanizer Side reboiler 2,914 kW (9. 96 MM Btu/hr); Demethanizer Reflux Chiller 7,259 kW (24.7 MMBtu/hr); Inlet Heaters 482 kW (1.6 MMBtu/hr)

2 x Deethanizer Fractionation: Tower 2,900/4,350mm ID x 8,480/27,770mm s/s;Deethanizer reboiler 19,041 kW (65.0 MMBtu/hr); Deethanizer Condensers 13,614 kW (46.4 MMBtu/hr), Deethanizer Reflux Pumps 315m3/hr, Deethanizer Feed Pumps 285 m3/hr, Deetahnizer Reflux Drums

2 x Depropanizer Fractionation: Tower 3,700mm ID x 30,100mm s/s;Depropanizer reboiler 12,427 kW (42.4 MMBtu/hr); Depropanizer Condensers 13,614 kW (46.5 MMBtu/hr), Depropanizer Reflux Pumps 485m3/hr, Depropanizer Reflux Drums

2 x Debutaniser Fractionation: Tower 2,150mm ID x 24,450mm s/s;Debutaniser reboiler 6,480 kW (22.1 MMBtu/hr); Debutaniser Condensers 8,051 kW (27.5 MMBtu/hr), Debutaniser Reflux Pumps 205m3/hr, Debutaniser Reflux Drums, Condensate Rundown Cooler 655 kW (2.24 MMBTU/hr)

Depentaniser Fractionation: Tower 1,900mm ID x 6,800mm s/s;Depentaniser reboiler 3,906 kW (13.3 MMBtu/hr); Depentaniser Condensers 4,413 kW (15.1 MMBtu/hr), Depentaniser Reflux Pumps 105m3/hr, Depentaniser Reflux Drums, Pentane Rundown cooler, Condesnate Rundown cooler

Condensate Stabilization: Stabilizer Tower:1,200mm IDx10,950mm s/s ;Stabilizer Reoboiler 1,861 kW (6.36 MMBtu/hr), Stabilizer Feed/Bottoms Exchanger, Stabilizer Condenser 486 kW (1.66 MMBtu/hr), Stabilizer Reflux Drum, Stabilizer Condensate Cooler, Stabilizer Reflux Pumps 9m3/hr, Stablizer Recyle Pumps 9m3/hr, Offgas Compressor Suction Drum, Offgas Compressor

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LPG Cooling & Rundown

2 x Rundown Chillers: Propane Product HP Rundown Chillers, 955 kW (3.27 MMBTU/hr)

Propane Product MP Rundown Chillers, 882 kW (3.0 MMBTU/hr)

Propane Product LP Rundown Chillers, 579 kW (1.98 MMBTU/hr)

Propane Product LLP Rundown Chillers, 559 kW (1.90 MMBTU/hr)

Butane Product HP Rundown Chillers, 472 kW (1.62 MMBTU/hr)

Butane Product MP Rundown Chillers, 454 kW (1.55 MMBTU/hr)

Butane Product LP Rundown Chillers, 152 kW (0.52 MMBTU/hr)

Steam Condensate System

Steam Condensate Drums : Steam Condensate Drums c/w Steam Condensate Pumps 95 m3/hr

Vent Steam Condensers, 3,431 kW (11.7 MMBTU/hr)

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L P G R E C O V E R Y P L A N T

P E T R O B R A S

Catu, Brazil (Northern Brazil)


Thermo Design was awarded a contract, in December 2002, with Petrobras to supply a TurboExpander C3+ Recovery Plant and a Condensate Stabilization plant to process a 2,500,000 m³/day (88 MMSCFD) of natural gas and 140 m³/day (880 bbl/day) of condensate. The project was completed in 2005.


Detailed design (process, mechanical, structural, electrical, instrumentation & control) and fabrication of the C3+ Extraction and Condensate Stabilization plants.

Preliminary and final HAZOP studies.

Shop fabrication of the process plant on a modular basis.

Automated control system with local and remote monitoring stations.

Registration of plant and equipment with Brazilian Authorities and Standards Agencies.

Shop testing of all equipment and systems.


Supply of spare parts for normal operation.

Construction supervision service during the site installation.

Responsibility for and start up of plant and operational performance test.

Personnel training for processes and operation.

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Inlet Gas Handling and Gas Pressure Boost

Gas Flowrate: 2,500,000 m³/day @ 37 Barg and 35°C (88 MMSCFD @ 527 Psig and 95°F)

Process Facilities: Inlet Separator, 2 x 100% Inlet Filter Coalescers, 2 x 100% Inlet Dry Gas Filters.

Gas Dehydration

Dehydration Technology: Mole Sieve Dehydration

Mole Sieve: Atofina/Zeochem

Gas Flowrate: 2,500,000 m³/day at 50 Barg (88 MMSCFD at 725 Psig)


No. of Mole Sieve Contactors: Three @ 50% Capacity (Two operating, one Stand By)

Gas Chilling, Turboexpansion & Deethanizer Tower

Pre-Gas Chillers: Brazed Aluminum Fin/Plate

Pre-Gas Chiller Duty: 3789 kW / 1989 kW (13 / 6.8 MMBTU/hr)

Low Temperature Separator: 46 Barg @ -32°C (669 Psig @ -36°F)

Deethanizer Fractionation: Full stainless 1829 / 1067 mm (72” / 42”) ID x 32m (105 ft) seam to seam. 30 valve trays for stripping Section 10 valve trays for rectifying Section 1530 kW (5.2 MMBTU/hr)+ 10% reboiler Full Stainless Reflux Accumulator 2 x 100% cryogenic pumps

C3+ Product Cooler: Air Cooler / Forced Draft 393 kW (1.3 MMBTU/hr)

Expander Type: Mafi Trench EC/Frame 3.0 Pre Boost

Operating BHP: 1324-1522 kW for Turbo Expander 1300-1498 kW for Inlet Boost Compressor

Operating RPM: 27,500-28,000


Sales Gas Compression

Gas Compressor Type: Dresser Rand 6 Throw, Single Stage HOS Reciprocating2,350,000 m³/day @ 15 Barg / 35 Barg (83 MMSCFD @ 218 Psig / 507 Psig 2 @ 100% (1 in Operation/1 in Stand by)

Compressor Driver: Electric Motor WEG 3600 kW (4828 HP) @ 1200 RPM

After-Cooler: Air Cooler / Forced Draft 3669 kW (12.5 MMBTU/hr)

Scrubbers: Suction and Discharge Scrubbers Compressor Suction and Discharge Bottles

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Condensate Stabilization Plant

Condensate Flow Rate: 60-140 m³/day @ 9-11 Barg and 20-50°C BSW Content 10-30% (11-25 USGPM @ 128-157 Psig and 68-122°F BSW Content 10-30%)

Process Facilities: Inlet Produced Condensate Separator, Stabilizer Tower, Heat Exchangers, Air-Coolers, Reflux Accumulator, Reflux Pumps

Stabilizer Tower: Packed Column 25mm (1”) – 304ss Pall Rings

Air Cooler Stabilizer Condenser (31 kW), Reflux Accumulator and Reflux Pumps

Stabilizer Reboiler: TEMA “R” BKU, 136 kW (464,163 BTU/hr)

Stabilizer Feed/Bottom Hex: TEMA “R” BEM, 280 kW (955,631 BTU/hr)

Stabilizer Product Cooler: Air Cooler / Forced Draft, 94 kW

Fuel Gas, Heat Medium & Drainage Systems

Heat Medium: 150 m³/hr (600 USGPM) Lubrax @ 255°C (491°F) 5275 kW (18.0 MMBTU/hr) Direct Fired Cylindrical Type Heater, Expansion Drum, 2 x 100% Circulation Pumps

Plant Drainage: Cold Drain Vessel, Closed Drain Vessel, Closed Drain Pumps

Fuel Gas: Fuel Gas Separator, 2 x 100% Fuel Gas Filters


Regeneration Gas Compressors: 2 x 100% Sundyne Centrifugal Gas Compressors 456m³/hr (16,100 ft³/hr)

Regeneration Gas Cooler: Air Cooler / Forced Draft 3730 kW (12.7 MMBTU/hr)

Auxiliary Equipment: Gas Cooler, Separator Filter / Coalescer & Heater

Regeneration Gas Heater: TEMA “R” BEU, 3956 kW (13.5 MMBTU/hr)

Control Systems

Process Control Functions: Foundation Fieldbus Control System: Includes Smar Foundation Fieldbus linking devices, Intrinsically Safe barriers, Fieldbus instrumentation & Smar AssetView asset management software to monitor Fieldbus and HART Instrumentation

Process Interlock and ESD Functions: Redundant Siemens 414 series PLCs used for

Main Plant Interlock and ESD.

Process Module Local Control: Siemens 315 series PLCs & MP- 370 touch screen used for local control and Interlock of package units (Turbo Expander, Sales and Regeneration Gas Compressors, Heat Medium Heater).

Human Machine Interface (HMI): Redundant Intellution IFIX Consoles in the control room, with external annunciator and trip consoles

Industrial Communications: Redundant Baystack model 470 Ethernet

Network: PLC and Fieldbus gateways linked by switches Control Room to Local Panel Room by fibre

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G A S S W E E T E N I N G & T U R B O E X P A N D E R L P G R E C O V E R Y P L A N T


Bagadja Gas Field, Turkmenistan


Thermo Design was awarded a contract, in December 2003, to supply LPG Recovery Plant with a nominal inlet gas flow of 3,000,000 m

3/day @ 80 barg and 55°C (106 MMSCFD @ 1170 psig and

130ºF). The Plant consists of two (2) identical parallel trains with 3,000,000 m3/day capacity each, built

and delivered on a “turn-key” project basis. The project was completed in 2006 with ongoing operations support thru 2007.












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Inlet Gas Separation

Gas Flow rate: 130,000 m3/hr @ 8050 kPag and 55°C (110 MMSCFD @ 1170 Psig and 130°F)

Process Facilities: Inlet Gas Cooler, 3-Phase Inlet Separator, Hydrocarbon Flash Drum.

Gas Sweetening

Gas Flow rate: 1580 m3/hr @ 7930 kPag

(1.34 MMSCFD @ 1150 Psig)

Lean Amine Flow rate: 36.4 m3/hr (160 GPM)

Acid Gas Removal: < 2% CO2 & 4 ppmv H2S

Amine Contactor: 9308 kPag @ 70ºC (1350 Psig @ 160ºF), 20 Valve Type Trays, 3 Water Wash Valve Type Trays

Amine Regenerator: 345 kPag @ 150ºC (50 Psig @ 300ºF), 20 Valve Type Trays

Amine Reboiler: 2985 kW (10.2 MMBTU/hr) + 8% BKU Shell & Tube Heat Exchanger

Auxiliary Equipment: Amine Flash Drum, 620 kW (2.1 MMBTU/hr) + 10% Lean Amine Cooler (Air Cooled Exchanger), 4x100% Lean Amine Pumps, Amine Surge Tank, 2x100% Particle Filters, 1x20% Carbon Filter, 1975 kW (6.7 MMBTU/hr) + 15% Lean/Rich Amine Exchanger (Plate & Frame Heat Exchanger), Reflux Accumulator, 2x100% Reflux Pumps, 1300 kW (4.4 MMBTU/hr) + 15% Reflux Condenser (Air Cooled Heat Exchanger)

Gas Dehydration

Dehydration Technology: Mole Sieve Dehydration using Siliporite

Gas Flow rate: 1,610 m3/hr @ 7730 kPag and 50°C(107 MMSCFD @ 1120 Psig and 120°F)

Process Facilities: Three Mole Sieve Contactors (two in drying and one in regeneration mode), Inlet Gas Filter and Dry Gas After Filter.

Auxiliary Equipment: Lube Oil Circulation System

Gas Chilling & Turbo Expansion

Pre-Gas Chillers: Brazed Aluminum Fin/Plate Heat Exchanger with five (5) services integrated in one unit, 9270 kW (31.7 MMBTU/hr) total duty

Low Temperature Separators: 9310 kPag @ -100°C (1350 Psig @ -150°F)

Turbo Expander: Mafi Trench EC/Frame 2.50; Operating BHP: 446 HP for Expander, 443 HP for Compressor; Operating RPM: 13,200 – 17,700


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Deethanizer Fractionation: Deethanizer Tower with 33 Valve Trays, 880 kW (3.0 MMBTU/hr) + 10% Reboiler,; Overhead Condenser (Fin/Plate Heat Exchanger); 13400 kg/h Capacity Overhead Compressor, Compressor Suction Scrubber & 462 kW (1.58 MMBTU/hr) Compressor Discharge Cooler (Air Cooled Heat Exchanger)

Condensate Stabilization: Stabilizer Tower: 25 mm (1”) 316SS Nutter NR1 Rings; 190 kW (0.65 MMBTU/hr) Reboiler; 200 kW (0.68 MMBTU/hr) + 10% Condensate Cooler (Air Cooled Heat Exchanger)

Debutanizer Fractionation: Debutanizer Tower with 24 Valve Trays, 928 kW (3.17 MMBTU/hr) Reboiler; 358 kW (1.2 MMBTU/hr) C5+ Product Cooler (Air Cooled Heat Exchanger); 1023 kW (3.5 MMBTU/hr) Overhead Condenser (Air Cooled Heat Exchanger); Reflux Accumulator & 2x100% Reflux Pumps


Regen Gas Compressor: Centrifugal Gas Compressor 370 m3/hr (13,080 ft3/hr)

Regen Gas Heater: 3085 kW (10.5 MMBTU/hr) Direct Fired Heater

Regen Gas Cooler: 3955 kW (13.5 MMBTU/hr) Forced Draft Air Cooler

Auxiliary Equipment: Regen Gas Separator

Utilities

Heat Medium System: 125,000 lb/hr @ 280°C (540°F) Heat Medium Oil Circulation, 5270 kW (18 MMBTU/hr) + 20% Horizontal Helical Coil Direct Fired Heater, Expansion Tank & 4x100% Heat Medium pumps

Instrument Air System: 210 m3/hr @ 800 kPag (7415 SCFH @ 116 PSIG) Instrument Air Flow Capacity, 2x100% Atlas Copco air compressors, I/A Pre-Filter, Dryer, After-Filter, Air Receiver & Exhaust Fan



Water Demineralization: 1260 kg/hr (5.5 USGPM) Water Capacity, Raw Water Pre-Filters, Water Softener, Brine Tank, 1x100% Charge pump, Reverse Osmosis System, Continuous Deionization Unit, 1x100% Distribution pump

Nitrogen Generation System: 1x100% Atlas Copco air compressor, Air Receiver, 2x100% Coalescing Filters, Carbon Filter, 1 kW (3412 BTU/hr) Electric Heater, 10 Nm3/h Capacity Membrane Nitrogen Generator, Nitrogen Receiver, 1x100% Pneumatic Nitrogen Booster Compressor

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Control Systems

I/O Points Approximately 2,000

Human Machine Interface: HMI system consists of three IBM workstations and a Report Printer. HMI displays both in English and Russian. Two workstations are redundant HMI’s that scan all the IO from the PLC and log the third engineering workstation for programming both the HMI and PLC systems.

Process Control Functions: One Programmable Logic Controller System (Siemens CPU317-2 DP processor) connected via Profibus to a series of ABB Remote IO panels and slave CPU’s that run some parts of the process in accordance with their own logic. All field wiring is terminated in the remote IO panels and thereby scanned and accessed by the PLC.

Flow Calculations: Performed by main CPU or by designated flow computers as per AGA3 specifications.

ESD Functions: Designated CPU that runs ESD logic, monitors status of its inputs (ESD Push Buttons, Gas/Fire Detectors, etc.) and generates Emergency Shut Down of 3 levels to the rest of the system. ESD outputs are hardwired to the process control system to provide reliable ESD function.The rest of the data is shared through ProfiBus communication.

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C O N D E N S A T E S T A B I L I Z E R & U T I L I T E S

I R A N I A N C E N T R A L O I L F I E L D S C O M P A N Y

Shanul, Varavi, and Homa Gas Treating Plant,Iran



Thermo Design was awarded a contract, in December 2004, to supply a condensate stabilization Plant and plant utilities packages. The project was completed in December 2006.

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Detailed Design (process, mechanical, electrical, civil, instrumentation and control) and fabrication of the condensate stabilization plant and plant utilities packages


Interconnecting Pipe rack and Underground Piping – Design, supply of Raw Materials and supervision of installation

DCS, ESD and F&G Control Systems for All New Units

Design of Equipment Foundations & Concrete Piles

Design of Building Structures Including HVAC & Internal Services

Electrical Installation on Skid Packages to Skid Edge Junction Boxes

Utility Substation and Process Substation Switchgear and MCC Equipment

Yard Lighting and Task Lighting

Design of Concrete Cable Trenches

Interconnecting Electrical Cables, and Site Grounding Materials

DC and AC UPS systems

Site Construction Supervision

Pre-Commissioning / Commissioning

Customer Training, Startup and Performance Test

Initial Fill of Lubricants, Fluids and Process Media for Thermo Design Equipment

2 Year Operating Lubricants, Fluids and Process Media for Thermo Design Equipment

Material Selection & Corrosion Report

Civil Design for Thermo Design Equipment Areas including roadways, crossings, site drainage

Off Spec Condensate Storafe & Transfer

Equipment Fireproofing Design

Sanitary System Design

Storm Sewer System Design

Fire Detection and Monitoring Systems & Fire Fighting Facilities, including Pumping Stations, Fire Water Main Piping and Fire Water Tank

Spare Parts for Startup and 2 Years Operation

Special Tools for Equipment Supplied

22



Stabilization

Condensate Stabilization: 20,000 bbl/day Condensate flow rate. Condensate heater –duty 6 MW @205degC; HP flash drum 2134 mm ID x 9144 mm s/s, DP 50 barg at 170degC:LP flash drum 2134 mm ID x 9144 mm s/s, DP 15 barg at 170 deg C: Condensate stabilizer 3348/1372 mm ID x 12,446 mm s/s; Stabilizer reboiler TEMA R BKU, duty 2800 kW; stabilizer overhead condenser, duty 217 kW; overheads accumulator; 3 stage off gas compression, total duty 461 kW, final discharge pressure 100.7 barg

Utilities

Heat Medium System: 175,000 lb/hr @ 260°C (482°F) Heat Medium Oil Circulation, 4325 kW (14.77 MMBTU/hr) Vertical Cylindrical Coil Direct Fired Heater, Surge drum;2x100% Heat Medium pumps,88,7 m3/hr at 4.15 bar; Filter

Instrument Air System: 1250m3/hr @ 11 barg (8821SCFH @ 160 PSIG)Instrument Air Flow Capacity, 3x50% oil flooded screw air compressors, I/A Pre-Filter, 3x50% Dryers, After-Filter, Air Receiver & Exhaust Fan

Diesel Storage/ Transfer: 37m3 storage tank, loading facility, dual transfer pumps,

filter.

Fuel Gas: HP Fuel Gas Drum, 1829 mm ID x 3048 mm s/s, DP 25.3 barg at 95 °C; HP fuel gas heater, duty 1083 kW; LP fuel gas drum, 1087 mm ID x 3000 mm s/s DP 8 barg at 95 deg C; LP fuel gas heater, duty 247 kW

Cooling Water: Expansion Drum; 2 Circulating pumps, 199 m3/hr at 3.6 bar; 2 refrigerant packages, 75 m3/hr

Firewater System 16,000m3 Storage tank; 3 Centrifugal pumps (1

electrical, 2 diesel), duty 908.4 m3/hr at 12 bar

Off-Spec Condensate 550m3 Storage tank; degassing boot; recycle pump

Control Systems

Process Control Functions Yokogawa Centum CS-3000 Distributed Control System (DCS) containing 4 Field Control Station (FCS). Process control functions using singular I/O; SD3 functions using redundant I/O.

ESD and Fire & Gas Safety Systems Yokogawa ProSafe-RS, fully redundant.

Package Control Systems (6) Schneider Quantum PLC.

Human Machine Interface (HMI) Yokogawa Centum CS-3000 HIS consoles (14)

Industrial Communications Network DCS via Vnet IP; PLc and MCC subnet via Ethernet (fully redundant hardware);

Control Room to Instrument Technical Rooms (2) by redundant fibre;

Motor control via TCP Modbus to Telemechanique PLC

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Flare System

Flare Type: Air Assisted

HP Flare Capacity: 1,214 Tonnes/hr (2,675,378 lb/hr) (607 Tonnes/hr per flare)

LP Flare Capacity: 25 Tonnes/hr (55,125 lb/hr)

Flare Design Criteria: Stack Velocity = 1.0 Mach (HP Flare) Stack Velocity < 0.5 Mach (LP Flare) Ground Level Radiation Level < 9.4 kW/m2

Auxiliary Flare Equipment: Condensate Separation and Pump out Four Pilot Burners with Electronic Ignition and Automatic Re-Light.

Drainage Systems

Oily Water/Accidental Oily Water Drainage & Treatment System: Waste Effluent disposal package, IGF chemical

treatment, evaporation pond, sanitary treatment package.

Hydrocarbon Liquid Burn Package: HC Liquid Drum, Pumps, 30m3/h wet liquid burn

package, burn pit

Plant Drainage Systems: Full Plant Flare and Process Drainage Requirements.Flare Knockout Drums Liquid Sump Pumps; u/g drainage tanks.

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S T I M U L P R O C E S S I N G F A C I L I T Y

Z A O S T I M U L , R U S S I A

Orenburg Region, Russia (Southwest Russia)


Thermo Design was awarded a contract with ZAO Stimul, (an independent joint-stock company and major share holder: Gazprom) to expand the existing facilities of an Oil & Gas Processing Plant near the Orenburg Region of Russia. The scope of the project includes the design and supply of equipment to upgrade the existing train, and supply an additional train, each with the ability to process reservoir fluids to a maximum of 500,000 tonnes/year in product crude oil. In addition, the design services for the future phases of the plant expansion were to be completed, including one more processing train to bring the production of the plant to 1,500,000 tonnes/year. The project was completed in 2008


Design and supply of additional equipment for existing oil & gas processing train to improve quality of oil separation, dehydration and desalination.

Design of new water treatment facilities for existing and future trains.

Design and supply of new oil & gas processing trains.

Design and supply of additional utility systems required for operation of new equipment. (existing facilities)

Design and supply of flare system required for operation of existing and new equipment.

Registration of plant and equipment with Russian Authorities and Standards Agencies.


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Preliminary Separation

Feed Flow rate: Liquid: 255 m3/hour at 16 barg

Vapour: 71,140 m3/hour at 16 barg

Process Facilities: Inlet Manifold, LP Separator

Inlet Manifold Capacity: 10 Inlet Tie-in Points

Separator Type: 3-Phase, Horizontal

Crude Dehydration / Desalination

Dehydration Technology: Electrostatic

Process Facilities: Crude Oil Dehydrator, Crude Oil Desalter, Crude Heater, Wash Water Pumps, Feed/Product Exchanger, Wash Water Exchanger

Dehydrator Type: 3-Phase, Horizontal Grid

Desalter Type: 3-Phase, Horizontal Grid

Crude Heating: Indirect Fired Heater, 960 kW, Forced Draft

Gas Handling

LP Gas Compression: 740 kg/hour. Reciprocating Separable Compressor with Electric Motor, Single-Stage Gas Compression, Vertical Direct-drive Air Cooling, Lube Oil Auxiliary System.

HP Gas Compression: 30,000 kg/hour. Reciprocating Separable Compressor with Natural Gas Driven Engine, Single-Stage Gas Compression, Horizontal Belt-driven Air Cooling, Lube Oil Auxiliary System.

Compressor Control: Compress control panel with interface to plant control system.

Heat Medium System

Heat Medium: 50% Weight Glycol at 95°C.

Process Facilities: Heat Medium Heater, Heat Medium Drain Drum with Pumps, Heat Medium Circulation Pumps.

Heat Medium Heating: Direct Fired Heater, 1484 kW, Forced Draft

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Flare & Drainage Systems

HP Flare Type: Smokeless, Air Assisted

HP Flare Capacity: 85105 kg/hr (120% of Maximum Flow)

LP Flare Type: Pipe Tip

LP Flare Capacity: 5170 kg/hr (120% of Maximum Flow)

Flare Design Criteria: Stack Velocity < 0.5 Mach Ground Level Radiation Level < 6.3 kW/m2 Smokeless Combustion up to 25% Design Capacity

Auxiliary Flare Equipment: HP Flare Air Blowers, HP Flare Knock-out Drum, LP Flare Knock-out Drum, 2 HP Flare Pilot Burners and 2 LP Flare Pilot Burners with Flame Front Ignition and Automatic Re-Light, Smoke Monitoring System.

Plant Drainage Systems: Full Plant Flare and Process Drainage Requirements.

Plant Drainage Equipment: HP Flare Knock-out Drain Drum with Pumps, LP Flare Knock-out Drain Drum with Pumps, Hydrocarbon Drain Drum with Pumps, Water Drain Drum with Pumps.

Produced Water Treatment Systems

Capacity: 3 Trains at 190 m3/hr.

Controlled Properties: Dissolved Oxygen, Oil, Suspended Solids.

Injected Chemicals: Demulsifier, Caustic, Aluminum Sulphate (Coagulant), Sodium Hydroxide (Caustic), Sodium Sulfite

Major Equipment: Degasifier Tank, Produced Water Booster Pumps, CPI/IGF Separators, Sludge Pumps, Coagulation Tank, Flocculation Tank, Sand Filters, Treated Water Transfer Tank, Treated Water Pumps, Service Water Pumps, Filter Backwash Water Settling Tank, Treated Water Storage Tank, Treated Water Booster Pumps Pumps, Chemical Tanks, Chemical Injection Pumps and Mixers.

Crude Oil Storage

Capacity: 4 Surge Drums at 200 m3 each.

Major Equipment: Crude Oil Surge Drums, Crude Oil Booster Pumps, Crude Oil Pipeline Pumps.

Instrument Air Package

Capacity: 2 Compressors at 5.2 Nm3/min each.

Major Equipment: Instrument Air Compressors, Air Filters, Air Dryers, Dry Air Receiver.

Fresh Water Treatment System

Capacity: 22.5 m3/hr.

Controlled Property: Iron

Major Equipment: Aeration & Storage Tank, Storage Pumps, Sand Filters, Backwash Tank, Backwash Pumps, Fresh Water Storage Tank, Fresh Water Pumps, Chemical Tanks, Chemical Injection Pumps and Mixers.

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G A S S W E E T E N I N G & T U R B O E X P A N D E R L P G R E C O V E R Y P L A N T


Yashyldepe Gas Field, Turkmenistan


Thermo Design was awarded a contract, in October 2004, to supply LPG Recovery Plant with a nominal inlet gas flow of 3,075,000 Sm3/day @ 65 - 80 atmospheres and 65ºC (109 MMSCFD @ 955 – 1175 psig and 150°F).











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Inlet Gas Separation

Gas Flow rate: 125,066 m3/hr @ 6590 - 10204 kPag and 65°C

(106 MMSCFD @ 955 – 1480 psig and 149°F)

Process Facilities: Inlet Gas Cooler, 3-Phase Inlet Separator

Gas Sweetening

Gas Flow rate: 125,066 m3/hr @ 6590 - 10204 kPag

(106 MMSCFD @ 955 - 1480 psig)

Lean Amine Flow rate: 81 m3/hr (357 USGPM)

Acid Gas Removal: < 2% CO2 & 4 ppmv H2S

Amine Contactor: 1829mm IDx18,288mm S/S 9308 kPag @ 70°C, 20 Valve Type Trays, 3 Water Wash Valve Type Trays

Amine Regenerator: 1524mmx15,850mm s/s 345 kPag @ 150°C (50 psig @ 300°F) 20 Valve Type Trays

Amine Reboiler: 6658 kW (22.7 MMBTU/hr) + 20% BKU Shell & Tube Heat Exchanger

Auxiliary Equipment: Amine Flash Drum, 1571 kW (5.4 MMBTU/hr) + 10% Lean Amine Cooler (Air Cooled Exchanger), 5x100% Lean Amine Pumps, Amine Surge Tank, 2x100% Particle Filters, 1x20% Carbon Filter, 4615 kW (15.8 MMBTU/hr) + 10% Lean/Rich Amine Exchanger (Plate & Frame Heat Exchanger), Reflux Accumulator, 2x100% Reflux Pumps, 3552 kW (12.1 MMBTU/hr)Reflux Condenser (Air Cooled Heat Exchanger)

Gas Dehydration

Dehydration Technology: Mole Sieve Dehydration using Siliporite

Gas Flow rate: 125,066 m3/hr @ 6590 - 10204 kPag and 52°C(106 MMSCFD @ 955 - 1480 psig and 126°F)

Process Facilities: Three Mole Sieve Contactors (two in drying and one inregeneration mode), Inlet Gas Filter and Dry Gas After Filter.

Auxiliary Equipment: Lube Oil Circulation System

Gas Chilling & Turbo expansion

Pre-Gas Chillers: Brazed Aluminum Fin/Plate Heat Exchanger with five (5) services integrated in one unit, 1,100 kW (3.76 MMBTU/hr) total duty

Low Temperature Separators: 9308 kPag @ -101°C (1350 Psig @ -150°F)

Propane Compressor 2xMycom P3225SSC-LBL; Required power 566 kW

Turbo Expander: Mafi-Trench EC/Frame 2.50;

376-634 HP for Expander, -628 HP for Compressor;

16,900 – 22,400 Operating RPM


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Deethanizer Fractionation: Tower 1676mm ID x 22,822mm s/s;Deethanizer reboiler 2751 kW (9.4 mmBtu/hr)+10%; Overhead Condenser (Fin/Plate Heat Exchanger); 13400 kg/h Capacity Overhead Compressor, Overhead 462 kW

(1.58 MMBTU/hr) Compressor Discharge Cooler (Air Compressor, Compressor Suction Scrubber & Cooled Heat Exchanger)

Condensate Stabilization: Stabilizer Tower:1067mm IDx17,374mm s/s ;25 mm (1”) 316SS Nutter NR1 Rings; 2145 kW (7.3 MMBTU/hr) Reboiler; 200 kW (0.68 MMBTU/hr) + 10% Condensate Cooler (Air Cooled Heat Exchanger)

Debutanizer Fractionation: Debutanizer Tower 1524mm IDx23,467mm s/s with 32 Valve Trays, 3231 kW (11.03 MMBTU/hr) +15%Reboiler; 2920 kW (9.97 MMBTU/hr) C5+ Product Cooler (Air Cooled Heat Exchanger); 3640 kW (12.4 MMBTU/hr) Overhead Condenser (Air Cooled Heat Exchanger); Reflux Drum & 2x100% Reflux Pumps


Regen Gas Compressor: Centrifugal Gas Compressor 31,536 m3/hr (26.7

MMSCFD)

Regen Gas Heater: 3631 kW (12.4 MMBTU/hr) +10%Direct Fired Heater

Regen Gas Cooler: 5400 kW (18.4 MMBTU/hr) Forced Draft Air Cooler

Auxiliary Equipment: Regen Gas Separator

Utilities

Heat Medium System: 550 m3/hr @ °C (°F) Heat Medium Oil Circulation,

19,780 kW (67.55 MMBTU/hr) Vertical Cylindrical Coil Direct Fired Heater, Expansion Tank & 4x100% Heat Medium pumps

Instrument Air System: 210 m3/hr @ 800 kPag (7415 SCFH @ 116 psig) Instrument Air Flow Capacity, 2x100% Atlas Copco air compressors, I/A Pre-Filter, Dryer, After-Filter, Air Receiver & Exhaust Fan



Water Demineralization: 1260 kg/hr (5.5 USGPM) Water Capacity, Raw Water Pre-Filters, Water Softener, Brine Tank, 1x100% Charge pump, Reverse Osmosis System, Continuous Deionization Unit, 1x100% Distribution pump

Nitrogen Generation System: 1x100% Atlas Copco air compressor, Air Receiver, 2x100% Coalescing Filters, Carbon Filter, 1 kW (3412 BTU/hr) Electric Heater, 10 Nm3/h Capacity Membrane Nitrogen Generator, Nitrogen Receiver, 1x100% Pneumatic Nitrogen Booster Compressor

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Control Systems

I/O Points Approximately 2,000 points in total with a mixture of ABB Intrinsically Safe Remote I/O mounted in hazardous locations and Siemens conventional I/O in controlled environments.

Human Machine Interface: The HMI system consists of three IBM workstations running Siemens WinCC version 6.0 and one Report Printer. The HMI screens display in English or Russian and can be toggled between the two languages with a mouse click. One HMI operates as a combined Engineering Work Station used for graphics/ PLC configuration changes, as well as an HMI for operation.The other two are dedicated to HMI functions. Local remote control buildings have touch panel controllers to supplement operator interface.

Process Control Functions: One Programmable Logic Controller System (Siemens CPU317-2 DP processor) is connected via Profibus to Remote IO panels. A separate Siemens 315-2DP CPU is dedicated for heater control.

Programming Languages: The following PLC programming languages are used: Function Block Diagram (FBD), Chart(CFC), Graph, and SCL

Flow Calculations: Performed by main CPU or by designated flow computers as per AGA3 specifications.

ESD Functions: One Programmable Logic Controller System (Siemens CPU315-2 DP processor) runs ESD logic, monitors status of its inputs (ESD Push Buttons, Gas/Fire Detectors, etc.) and generates Emergency Shut Down of 3 levels to the rest of the system. ESD outputs are hard-wired to the process control system to provide reliable ESD function.

Communications: HMI to PLC communication is via Ethernet. PLC to Remote I/O is via Profibus. Short distance communication is over copper and longer distances is over fibre-optic.

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C R U D E O I L & A S S O C I A T E D G A S P R O C E S S I N G P L A N T

K A R A K U D U K M U N A I / L U K O I L

Karakuduk Oil Field, Kazahkstan


Thermo Design was awarded a contract, in June 2007, to supply an Oil Processing Plant with a nominal inlet oil flow of 6,000 m³/day (37,740 BPD). The contract also included supply of an Associated Gas Processing plant designed for a capacity of 15,600 Nm³/hr @ 200 kPag and 30ºC (14 MMSCFD @ 29 psig and 86°F). The Complex Gas Treatment Plant (CGTP) was operational in December 2008, while the Central Oil Treatment Plant (COTP) was operational in February 2009.


Detailed Design (process, mechanical, electrical, instrumentation and control) and fabrication of the Crude Oil and Gas Processing Plants.



Supervision of field assembly of the modular Thermo Design supplied equipment.



Registration of plant and equipment with local authorities and standards agencies.

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Preliminary Separation

Feed Flow Rate: Liquid: 310 m3/hour (47,000 BPD) at 500 kPag (73 psig)

Process Facilities: Inlet Manifold, Free Water KnockOut

Inlet Manifold Capacity: 10 Inlet Tie-in Points

Free Water KnockOut Type: Direct Fired 3-Phase, Horizontal

Free Water KnockOut Duty: 2700 kW (920,000 BTU/hr)

Crude Dehydration / Desalination

Dehydration Technology: Mechanical/ Electrostatic

Process Facilities: Crude Oil Dehydrator, Crude Oil Desalter, Wash Water Pumps, Feed/Product Exchanger, Wash Water Exchanger, Gas Boot Compressor

Dehydrator Type: Direct Fired, Mechanical 3-Phase, Horizontal

Dehydrator Duty: 2700 kW (920,000 BTU/hr)

Desalter Type: Electrostatic 3-Phase, Horizontal Grid

Associated Gas Compression

Gas Compressors: Three @ 50% capacity

Gas Compressor Model: Dresser Rand 6HOS2

Gas Compression: 7,800 Nm³/hr (7 MMSCFD) each. Reciprocating separable compressors with 860 kW (1150 HP) natural gas engine drivers, two-stage gas compression with process scrubbers and coolers.

Auxiliary Equipment: Compressor lube oil circulation system, engine cooling systems, pulsation bottles.

Compressor Control: Dedicated PLC with local control integrated into overall plant network.

Gas Chilling & NGL Recovery

Feed Flow Rate: 7,800 Nm³/hr @ 38°C (7 MMSCFD @ 100°F)

Gas / Gas Exchanger: TEMA C NEN 237 kW (0.8 MMBTU/hr), Two Bank

Gas / Liquid Exchanger: TEMA C NEN 85 kW (0.3 MMBTU/hr)

Gas Chiller: TEMA C NKN 477 kW (1.6 MMBTU/hr)

Low Temperature Separator: Operating -5 °C (23 °F)

Refrigerant: Propane evaporating at -9 °C (16 °F)

Refrigerant Propane Process: Screw compressor, refrigerant accumulator, filter drier, air cooled condensers and shell / tube evaporative chillers.

Propane Condenser Duty: 572 kW (1.95 MMBTU/hr) air cooler, two bays.

Refrigerant Compressor: Two @ 100% Capacity / One spare

Mycom P200VSR.L; Required power 159 kW (215 HP)

Refrigerant Flow: 95 kg/min (12,540 lb/hr), Single train.

Refrigerant Compressor Driver: Caterpillar G3406TA; Natural Gas Engine

215 kW (288 HP) nominal rating.

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Auxiliary Equipment: Compressor lube oil circulation system, engine cooling systems.

NGL Fractionation: Deethanizer tower w/ random packing

TEMA 'BGU' Reboiler 480 kW (1.6 MMBTU/hr)

Utilities

Heat Medium System: 40 m3/hr (176 USGPM) @ 185°C (365°F) Heat Medium

Fluid, 1100 kW (3.75 MMBTU/hr) Direct Fired Heater, Heater Blower, Heat Medium Drain Drum & Two x 100% capacity Heat Medium pumps

Instrument Air System: 194 m³/hr @ 720 kPag (7372 SCFH @ 104 psig)

Two x 100% Atlas Copco compressors, I/A Pre-Filter, Dryer, After-Filter, Air Receiver

Nitrogen System: 10 Nm³/hr @ 65 barg capacity with 99% purity

Feed air compressor, feed air receiver, prefilters, electric heater, membrances, nitrogen buffer, boost compressor and nitrogen storage cylinders.

Flare & Drain Systems: 23,340 Nm³/hr HP flare and 300 Nm³/hr LP flare, stacks and associated control panel, HP flare KO drum, HP flare KO drain drum, 2x100% HP flare KO drain drum pumps, closed drain drum, closed drain drum pump.

Fuel Gas: Fuel Gas supply from plant sales gas line.

Control Systems

I/O Points Approximately 900 points.

Human Machine Interface: Three client stations, one engineering station, one server, and report printer. Siemens WinCC client stations. English and Russian display languages.Local control stations for compressor and heater control.

Process Control Functions: One redundant Siemens 417-4-2H PLC via Profibus to remote I/O modules. Three Siemens 414-3 PLCs connected to remote I/O modules for gas compressor control

Fire, Gas & ESD Functions: One redundant Siemens 417-4-2H PLC.

Communications: HMI to PLC communication is via Ethernet.

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H E A V Y C R U D E O I L A N D H E A T M E D I U M H E A T I N G P L A N T

L U K O I L - K O M I

Usinks, Russia



Thermo Design was awarded a contract, in March 2008, to supply a Heavy Crude Oil and Heat Medium Heating Plant designed for the Russian arctic. The inlet flow of 360m³/day (53,800 BOPD) of 17 API crude was heated from an inlet temperture of 10ºC to a final processing temperature of 115ºC via three stages of heat transfer. The contract also included supply of a heat medium system designed with a circulation rate of 2,040m

3/h (9,000 gpm) and total heat input of 44MW (150MMBTU/h). The project

delivery will be completed in the first quarter of 2009 with start up in late 2009.


Detailed Design (process, mechanical, electrical, instrumentation and control) and fabrication of the Crude Oil Heating and Heat Medium Units.



Supply of plant chemicals and lubricants.

Supervision of field assembly of the modular Thermo Design supplied equipment.



Registration of plant and equipment with local authorities and standards agencies.

35



Heat Exchangers Module

Feed Flow Rate: Dry Oil: 360 m3/hour (53,800 BPD)

BS&W: 60-80%

Feed/Product Exchangers Type: Plate and Frame

Feed/Product Exchangers Duty: (3) 50% Units – 1.6 MW each

1ST

Stage Exchangers Type: Plate and Frame

1ST

Stage Exchangers Duty: (3) 50% Units – 14.5 MW each

2nd

Stage Exchangers Type: Plate and Frame

2nd

Stage Exchangers Duty: (3) 50% Units – 4.2 MW each

Building Water Exchanger Type: Plate and Frame

Building Water Exchanger Duty: (1) 100% Unit – 2.5MW

Heat Medium System

Heat Transfer Fluid: Therminol 59

Circulation Pumps: (3) 50% Units – 1020m3/h (180 gpm), 200kW each

Heater Type: Forced Draught Vertical Cylindrical

Heater Duty: (3) 50% Units – 22MW (75MMBTU/h) each

Additional Equipment Heat Medium Expansion Drum, Heat Medium Drain Drum and Drain Drum Pump

Utilities

Building Water Heating System (2) 45m3/h (200 gpm) circulation pumps, expansion drum

Instrument Air System: Instrument Air Receiver

Nitrogen System: Nitrogen Receivers.

Control Systems

Control and MCC buildings: Included

I/O Points Approximately 300 points.

Human Machine Interface: One engineering station. English and Russian display languages.

Process Control Functions: One redundant Siemens CPU with Ethernet communications to central control room.

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A S S O C I A T E D P E T R O L E U M G A S T R E A T M E N T P L A N T

L I M I T E D L I A B I L I T Y C O M P A N Y M O N O L I T

Prirazlomnoye Oil Field, Nefteyugansk region of Khanty-Mansi Autonomy District, Russia.


Thermo Design was awarded a contract, in July 2008, to supply Modular automated Associated Petroleum Gas (APG) Treatment Plant with the capacity 190 mln.m³/year for the recovery of Dry Natural Gas, Propane-Butane liquids and stabilized condensate.


Detailed Design (process, mechanical, electrical, instrumentation and control) and Fabrication of the equipment for APG Treatment Plant.

GOST-R Certification of plant equipment and obtaining of the Permit to use for the equipment.



Supply of plant chemicals, lubricants.

Assembly, commissioning and startup supervision.

Personnel training.

Equipment transportation to site.


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Inlet Compression

Feed Gas Flow Rate: Low Pressure: 100,000,000 Nm³/yr +15% at 3 kPag (10.1 MMSCFD +15% at 0 Psig) High Pressure: 90,000,000 Nm³/yr +15% at 450 kPag (9.1 MMSCFD +15% at 65 Psig)

Gas Compressors: Two LP Compression trains at 50% capacity Two HP Compression trains at 50% capacity (HP Compressor combines High pressure feed gas and LP compressor discharge gas)

Gas Compressor Type: LP Compressor: Dresser Rand 6HOS4 reciprocating LP Compressor:: Dresser Rand 6HOS2 reciprocating

Compressor Ancillaries: Auxiliary lube oil pumps, coolers, filters, lube oil storage tanks, compressor crankcase heater; suction scrubbers, pulsation bottles, LP Compressor hydrocarbon liquid transfer pumps

Compressor Driver Type: LP Compressor: 574 kW Caterpillar 3516LE engine HP Compressor: 940 kW Waukesha L7044GSI engine

Driver Ancillaries: Engine drive auxiliary cooler; storage tanks, exhaust/intack piping, muffler Engine & compressor housed in heated building with overhead crane.

Gas Dehydration Dehydration Technology: Mole Sieve Dehydration

(Using dry gas recycle for regeneration)

Gas Flowrate: 225,000,000 Nm³/yr @ 2.4 MPag and 40°C(22.7 MMSCFD @ 350 Psig and 104°F) Note: Flow rate includes regeneration gas recycled to HP compression train


Process Facilities: Two 100% capacity inlet gas filters Two 100% capacity mole sieve contactors Two 100% capacity dry gas filters Regeneration gas heating / cooling / separation

Gas Chilling & Lean Oil Absorption

Gas Chilling & Separation: Gas/Gas Exchanger (1.4 GJ/hr); Gas Chiller (6.8 GJ/hr) Low Temperature Separator, Lean Oil Scrubber, Condensate Pump (Two at 100% capacity) 30 m³/hr, Lean Oil / Condensate Exchanger (2.8 GJ/hr)

Deethanizer System: Deethanizer Tower, Deethanizer Side Reboiler (3.5 GJ/hr), Deethanizer Main Reboiler (8.4 GJ/hr)

Presaturation System: Presaturation Chiller (1.7 GJ/hr), Presaturation Separator, Presaturation Lean Oil Pumps (Two at 100% capacity) 40 m³/hr

38


Rich Oil Fractionator System: Rich Oil Fractionator (ROF), ROF Condenser (15.8 GJ/hr), ROF Reflux Drum, ROF Reflux Pumps (Two at 100% capacity), Hot Lean Oil Circulation Pumps (Three at 50% capacity) 275 m³/hr

Oil Purification System: Oil Purification (OP) Still, OP Still Condenser (3.4 GJ/hr), OP Still Reflux Drum, OP Still Reflux Pump (Two at 100% capacity), OP Still Reboiler (1.5 GJ/hr), OP Still Overheads Cooler (1.3 GJ/hr), OP Still Product Pump (Two at 100% capacity)

Lean Oil System: Lean Oil Heater (Uniflux Convection Type, 48.0 GJ/hr), Lean Oil Cooler (4.9 GJ/hr), Lean Oil Circulation Pump (Two at 100% capacity) 40 m³/hr

Liquid Fractionation

Depropanizer System: Depropanizer Tower, Depropanizer Condenser (9.2 GJ/hr), Depropanizer Reflux Drum, Depropanizer Reflux Pumps (Two 100% capacity) 60 m³/hr, Depropanizer Reboiler (10.4 GJ/hr)

Debutanizer System: Debutanizer Tower, Debutanizer Condenser (5.4 GJ/hr), Debutanizer Reflux Drum, Debutanizer Reflux Pumps (Two 100% capacity) 18 m³/hr, Debutanizer Reboiler (10.4 GJ/hr)

Condensate Stabilization: HC Liquids Separator, HC Liquids Stabilizer, HC Liquids Reboiler (370 MJ/hr), Condensate Cooler

Propane Refrigeration

Refrigerant Propane Process: Two 50% capacity trains each consisting of: Compressor, scrubber, economizer, oil separator, condenser, accumulator, filter drier

Refrigerant:: Propane evaporating at -25 °C (–14 °F)

Refrigerant Compressor: Mycom P3225SSC Compound (3645 MJ/hr refrigeration capacity)

Refrigerant Compressor Ancillaries: Auxiliary lube oil pump, cooler, filters

Refrigerant Compressor Driver: 605 kW Caterpillar 3512LE engine c/w gearbox

Driver Ancillaries: Engine drive auxiliary cooler; storage tanks, exhaust/intack piping, muffler Engine & compressor housed in heated building with overhead crane.

Utilities

Heat Medium System: Circulation 30 m3/hr @ 135°C (130 USGPM @ 275°F), Heat Medium Heater 750 kW (2.6 MMBTU/hr Bath Type), Heat Medium Pumps

Instrument Air System: Two Rotary Air Compressors (192 Nm3/h @ 1050 kPag), I/A Pre-Filter, Dryer, After-Filter, Air Receiver

Nitrogen Generation System: Packaged membrane module (10 Nm3/h @ 6550 kPag & 99% purity), Storage cylinders


Flare System: Flare KO Drum, Flare Drain Drum, Drain Pumps

Drain System: Closed Drain Drum, Drain Drum Pump

39


Control Systems

I/O Points: Approximately 2,000

Overall: The overall system is based on DeltaV version 10.3 and consists of three independent systems, PCS, CCS, and ESD, each with redundant controllers and local I/O. System and marshalling cabinets are installed in the Central Control Room. Instrumentation is connected via skid-edge junction boxes through home-run cables to the control room. Two Operator Stations, one Engineering Station, and one Archive Server are incorporated for all systems.

PCS: The Process Control System performs all normal control functions for the plant including analog monitoring and control, discrete control and status monitoring of motors and solenoid valves, mole sieve dehydration sequencing, etc.

CCS: The Compressor Control System performs all monitoring and control for six compressors. There is a common set of redundant controllers connected to I/O racks which are dedicated to each individual compressor.

ESD: The Emergency Shut Down system is responsible for all safety-related functions for the main plant and compressor units. Emergency shut down actions are independent of the PCS and CCS systems. Gas detection and fire detection is also part of the ESD system.

Operator Stations: Two dual-monitor capable operator stations are provided. The platform for these stations is Dell model T3400 workstations running MS Windows XP. These stations display both in English and Russian.

Engineering Work Station: The Engineering Wok Station is a DeltaV Pro Plus station on the Dell T3400 platform running MS Windows XP. From here, all control module and operator screen changes are performed, stored and down-loaded to the appropriate operator station or controller.

Archive Server: The Archive Server is a DeltaV Continuous Historian running on a Dell T3400 workstation running MS Windows XP. This server makes historical data available to the operator stations and engineering station.

Communication Network: The communications network is redundant Ethernet including redundant switches.

40

I N T E G R A T E D G A S T R E A T M E N T P L A N T

T N K - B P

Pokrovka Field, Orenburg Region, Russia


Thermo Design was awarded a contract to supply an Integrated Gas Treatment Plant with a nominal inlet gas flow of 450,000,000 m3/year @ 0.12-0.25 MPag and 10°C.


Detailed Design (process, mechanical, electrical, instrumentation and control) and fabrication of the Gas Treatment Plant.


Registration of the plant with Russian Authorities (GOST-R and Permit to Use)







41



Feed gas compression unit;

Condensate stabilization/sweetening unit;

Gas Sweetening Unit;

Gas Dew point Control & Liquids Fractionation Unit;

Glycol Regeneration Unit;

Sulfur Recovery Unit;

Sulfur Pelletting Unit;

Pelletized Sulfur Storage and Handling Facilities;

Nitrogen and Instrument Air Generation Unit;

Heat Medium System;

Demineralized Water Treatment Unit;

Fuel Gas Treatment Unit

Feed gas compression unit

The inlet gas compression systems consist of three 33% capacity Feed Gas Compressor Trains. The compressor trains provide three stage compression of the plant feed gas feed stream. The three compression trains operate in parallel. The plant feed gas streams boosted to the operating pressure of the Module AGSMDEA Gas Sweetening. The gas compression trains are designed for 52,000 Nm³/hr total or 17,333 Nm³/hr each at a suction pressure of 0.12 MPag and a discharge pressure of 6.1 MPag.

Condensate stabilization/sweetening unit

The objective of the Condensate Stabilization/Sweetening Unit is to remove H2S from the sour hydrocarbon liquids produced in the compression process so it can be processed in the Fractionation Unit. The liquids are also partially stabilized through the removal of ethane and lighter components prior to being fed to the Depropanizer tower.

Gas Sweetening Unit

The objective of the MDEA Sweetening Unit is to remove H2S from the sour natural gas stream from the Feed Gas Compression Unit prior to entering the Hydrocarbon Dew point & Liquid Fractionation Unit. The MDEA Gas Sweetening Unit is a regenerative amine process for the removal of hydrogen sulphide and carbon dioxide from the gas stream. An aqueous solution of MDEA (methyl diethanol amine), at a concentration of 45 weight percent is used to sweeten the raw gas. This solution contains water, into which the gases dissolve into the amine solvent, containing the MDEA, with which the acid gases chemically react.

Gas HC Dew point Control & Liquids Fractionation Unit

The objective of the Hydrocarbon Dew point and Liquids Fractionation Unit is to remove heavy hydrocarbons from the natural gas stream to produce a Propane/Butane liquid blend and a C5+ condensate stream. The Gas Fractionation Unit utilizes mechanical propane refrigeration to cool the gas stream to -14°C and distillation towers to produce the liquid product streams. Ethane gas produced during distillation is compressed back to sales gas pipeline pressures. The gas is dehydrated by utilizing ethylene glycol.

42


Glycol Regeneration Unit

Water is removed from the natural gas entering the gas chilling equipment using an 80% weight solution of ethylene glycol (EG). The EG solution is sprayed onto the tube sheets of the gas/gas exchanger, gas/liquid exchanger and the gas chiller.

Sulphur Recovery Unit

The objective of the Sulfur Recovery Unit is to convert H2S from the acid gas feed to a liquid sulphur product. A three bed Claus Unit is provided to achieve a SOR sulfur recovery of 98.2%. The liquid sulphur product has a purity of 99.95%.

Sulphur Pelletting Unit

The objective of the Unit is to granulate the liquid sulfur and produce the sulphur pallets. The unit process is based on Sandvik technology.

Pelletized Sulphur Storage & Handling Facilities

The objective of the unit is to bag and store the sulphur product.

Nitrogen and Instrument Air Generation Unit

Nitrogen is generated between 95.0% to 99.5% purity, inert gas, for the purposes of fire suppression and utility requirements. The nitrogen system has a design capacity of 10 Nm³/hr at a supply pressure of 1.0Mpag. The Nitrogen generation skid has four sub-systems: inlet air compression and preparation, nitrogen generation via the Generon permeable membrane modules, high pressure nitrogen compression as well as nitrogen storage and distribution

Dry instrument air is supplied for operation of plant instrumentation. The instrument air package has a design capacity of 194 Nm³/hr at a supply pressure of 0.72 MPag. The instrument air unit includes inlet air compression and air drying.

Heat Medium System

Process heating duty is supplied by heat medium fluid supplied at 275°C from the heat medium skid.

Heat medium returns from the plant to the Heat Medium Expansion. The Heat Medium Pumps (two 100% capacity units) take suction from the heat medium heater and circulate the hot oil through the Heat Medium Heater. This heater is a direct-fired heater and has a capacity of 30,830 MJ/hr.

Demineralised Water Treatment Unit

During distillation is compressed back to sales gas pipeline pressures. The gas is dehydrated by utilizing ethylene glycol.


Fuel gas for plant operation will be obtained from the sales gas line during normal plant operation. During plant start-up, fuel gas will be provided by the Client. TDE has included a fuel gas conditioning skid that includes and electric heater, pressure control station and fuel gas scrubber to remove liquids and impurities from the gas stream.

Engineering Only Projects

S I R R I I S L A N D

G A S G A T H E R I N G & N G L R E C O V E R Y P L A N T

Oil Industries’ Engineering & Construction, Persian Gulf, Iran

(existing facilities)


Thermo Design was contracted, in July 2004, to develop the Basic Engineering Design for a sour gas processing and liquids recovery plant for installation on Sirri Island in the dessert marine environment of the Persian Gulf.

Plant nominal inlet gas flow is 4 MMm3/day (142 MMSCFD) of wet sour gas and 106 m

3/day (665

BBL/day) of hydrocarbon liquids. The project was completed in June 2005.

The plant is designed to yield the following final production:

! Residue Gas : 3.1 MMm3/day (108.4 MMSCFD)

! Propane: 22,580 kg/h

! Butane: 13,700 kg/h

! Pentane: 5,680 kg/h

! Hexane+: 3,750 kg/h

! Stabilized Condensate: 2,100 kg/h

The contract included submission of over 1,400 engineering documents in Process, Safety, Civil,Structural, Building, Piping, Rotary Equipment, Fixed Equipment, Electrical, Telecommunication, Instrumentation & Control disciplines.

1

E N G I N E E R I N G O N L Y P R O J E C T S

P R O J E C T D E L I V E R A B L E S

Thermo Design generated engineering documents as a result of design, optimization & modification of conceptual information. A summary of generated documents by Thermo Design follows:

Process

! Basis of Design, Conceptual Study Report

! Process Simulations

! Heat and Mass Balances

! Flow Diagrams (BFD, PFD, UFD)

! P&I Diagram (Process, Utility, Offsite)

! Philosophies (Vent, Relief, Blow down, Drainage)

! Process Data Sheet for Equipment, Systems, Packages, Control/Safety Valves

! Flare Load Summary

! Process/Utility Line Sizing

! Line Lists

! Material Selection Report

! Equipment List / Utility Summary

Safety / Environment

! HAZOP / HAZID Study

! Consequence Analysis Study

! Safety Layout

! Area Classification

! Fire Zones & Fire Partitioning

! Passive Fire Protection

! Active Fire Fighting

! Fire & Gas Detection

! Emergency Shut-Down

! Emergency Escape Routing

! Environment Protection

Piping / Layout

! Piping Material Specifications

! General/Unit Plot Plans

! Equipment Layout (3D PDMS)

! Critical Line Study (3D PDMS)

! Piping Stress Calculation

! Single Line Pipe Rack Drawings

! Preliminary Material Take Off

! Line List

! Test Procedures

2


Fixed Equipment

! Specification / Mechanical Data Sheet / Test Procedures for Double Wall Tanks, Fixed/Floating Roof Storage Tanks, Air Coolers, Shell & Tube Heat Exchangers, Cold Heat Exchangers, Pressure Vessels

Rotary Equipment

! Mechanical Data Sheet, Specification for extensive variety of Compressors, Expander, Pumps, Utility packages, Loading Arms, Gas Turbine Generators

Civil & Structural

! Design Specification & Design Drawing for Underground, Roads & Paving, Trench, Earthwork, Drainage, Foundations, Concrete Works, Flood Control, Seawater Intake, Fire Proofing, Landscaping

! Loading of Critical Line for Pipe Rack and Supports

! Preliminary Load of Equipment & Critical Line for foundation design

! 3-D Model for Steel Structure

! Preliminary Material Take Off for Civil Material, Steel Structure & Concrete Works

Building & Architectural

! Building Functional Specification for Industrial & Non-Industrial Buildings

! Building Material Specification

! Schematic Architectural Drawings & Dimensions

! Preliminary Material Take Off for Building Material

HVAC

! Design Criteria, Specification, Data Sheet for HVAC & Plumbing in optimized condition

! Duct, Pipe & Instrument Diagrams

! Preliminary Material Take Off for HVAC & Plumbing

Electrical

! Electrical Design Philosophy

! Electrical Load List

! Hazardous Area Classification

! Data Sheet & Specification for Electrical Equipment

! Load Flow/Shedding Study

! LV, MV Single Line Diagram

! Main Cable Route Layout

! Substation / Control Room Equipment Arrangement

3


Instrument & Control

! Instrumentation Data Sheet & Specification

! PCS, ESD, F&G Specification

! Control Systems Diagram / Logic Diagrams / Cause & Effect Matrix

! Instrument Index

! I/O List & Summary

! SIL Dossier, Test & Calibration Procedure

! Control Building / Technical Equipment Room / Main Cable Route Layout

! Electrical Power & Air Consumption List

Telecommunication

! Telecommunication System Philosophy & Specification

! Telecommunication Equipment Data Sheet & Lists

! Telecommunication Block Diagram

! Link Budget & Design Report for Fiber Optic Ring

! Radio Propagation & Coverage Study for radio systems

! Power Consumption List

! Equipment Layout Drawing for Telecommunication

! Radio Aerial Layout


P R O J E C T E Q U I P M E N T S C O P E

The engineering documentation was prepared for the process & utility equipment summarized below.

Nasr Reception Facilities

Sirri-E Slug Catcher Facilities

NASR & ESFAND Production Stations

LP Compression Facilities

4


NGL Plant

! Feed gas compression station.

! Acid gas removal unit.

! Acid gas incinerator.

! Gas dehydration unit.

! Mercury Removal

! NGL recovery unit to extract C3+ from the gas.

! NGL fractionation to Propane, Butane, Pentane and C6+.

! NGL refrigeration.

! Cryogenic Propane and Butane storage.

! Propane and Butane boil-off gas recovery.

! Loading facilities for Propane and Butane export by fully refrigerated gas carriers.

! Pentane storage and export ship loading facilities.

! Condensate stabilization, storage and export to ship loading facilities.

Onshore LP Compression Station Utilities

! Instrument and plant air systems (from existing facilities)

! Nitrogen (if required) from new NGL plant facilities

! Fire Water (from existing facilities)

! Utility Water (from road tanker)

! Flare System (tied into existing facilities)

! Power Supply (imported from new NGL plant facilities)

! Closed & Open Drain systems (tied into existing facilities)

NGL Plant Utilities

! Fuel gas system.

! Instrument and plant air systems

! Nitrogen System

! Raw Water / Fire Water / Potable Water system

! Steam generation

! Power Generation/Distribution

! Fire Fighting System

! HP, LP, and Loading Flare Systems

! Closed & Open Drain systems

! Burn Pit

! Amine Drain system

! Effluent Treatment/Disposal system

5


O I L & G A S P R O C E S S I N G F A C I L I T Y N A T U R A L G A S D E E T H A N I Z A T I O N U N I T

F E A S I B I L I T Y S T U D Y A N D C O N C E P T U A L D E S I G N

BRASKEM A-150, Camacari Petrochemical Complex, Bahia, Brazil

(existing facilities)


Thermo Design was awarded a contract, in December 2005, for feasibility study, conceptual design, and additional engineering / site services for the revamp of existing natural gas deethanization unit, for the following original production:

! Natural Gas: 2.015 MMm³/day (71.2 MMSCFD)

! Ethane: 8,300 kg/day

This engineering project is being completed in several stages, and will be completed in February 2007.

The scope of the studies includes analysis of existing equipment to determine the restrictions, and revamp of existing equipment to achieve design flow rates; also to analyze 8 new proposed feed cases,with the conceptual design phase including further detailed engineering on the 2 Thermo Design recommended cases.

The proposed cases to be analyzed include a combination of flow rates of 2, 3, and 5 MMm3/d, of natural

gas feed from 3 different facilities, with different outlet specifications, 8 cases in total.

The contract includes submission of engineering documents in Process, Mechanical, Rotary Equipment, Fixed Equipment, Instrumentation & Control disciplines.

6



Thermo Design will generate engineering documents as a result of process design, optimization and modification of operating and conceptual information. A summary of documents to be generated for each of the cases analyzed by Thermo Design follows.

Process

! Basis of Design

! Description of Process Modifications

! Alternative Solutions

! Preliminary Sizing of new Equipment

! List of New and Modified Equipment


! Detailed Process M&H Balances

! Utility M&H Balances


! P&I Diagram (Process)

! Thermal Rating of Existing Heat Exchangers

! Process Data Sheet for new, modified, and existing Equipment, Control/Safety Valves



! Feasibility Study Final Report

! Conceptual Design Final Report

! Process Design Book

General

! Budget Cost Estimates for each study case


! Risk Assessment

Piping / Layout


Fixed Equipment

! Mechanical Data Sheets for new Shell & Tube Heat Exchangers, Cold Heat Exchangers, Pressure Vessels

Rotary Equipment

! Mechanical Data Sheet for Existing Compressor Re-rating, and New Compressors, Pumps


! Description of New and Modified Control Loops

! Instrument Index

! List of Analyzers

7


P R O J E C T E Q U I P M E N T S C O P E

The engineering documentation was prepared for the process & utility equipment as summarized below:

Natural Gas Deethanization Plant

! Feed Gas Compression (new and existing)

! CO2 removal (new)

! Gas Dehydration unit (new and existing)

! Mercury Removal (new)

! Gas fractionation to Methane, Ethane and C3+. (existing)

! Nitrogen removal (new)

Natural Gas Deethanization Plant Utilities Analyzed

! Fuel gas system

! Instrument and plant air systems

! Quench Water System

! Propylene Cooling System

! Regeneration Gas System

8


Z A I K I N S K O Y E G A S P R O C E S S I N G P L A N T E X P A N S I O N

O R E N B U R G N E F T O F R U S S I A

OrenburgNeft of Russia (currently a division of TNK - BP), Tulipan, Russia


Thermo Design was awarded a contract, in April 2006, with TNK-BP for select-stage engineering of the planned Phase 2 expansion of the Zaikinskoye Gas Processing Plant, built previously by Thermo Design. The scope of the project included the technical evaluation of multiple processing options and preparation of budget cost estimates and schedules. This allowed the client to complete an economic evaluation to determine the best option for the design and supply of equipment for the plant upgrade. Each train has a design capacity of 130,000Nm³/hr (110 MMSCFD) of natural gas. The project wascompleted in September 2006.

9


The Phase 2 Expansion options evaluated are as follows:

! Base Case – Duplication of existing Dehydration, Gas Processing and Mechanical Refrigeration units

! De-bottleneck option to meet gas pipeline water and hydrocarbon dew point specifications for the future plant capacity and gas compositions. This option included new glycol regeneration and gas chilling units.

! Base case with liquids fractionation (2 trains) into propane, butane and condensate products.

! Base case with liquids fractionation (1 train) into propane, butane and condensate products.

! Base case with liquids fractionation (2 trains) and oil stabilization. Includes 2 trains of oil stabilization each capable of 325 m

3/h (49,000 bpd).

! Deep Cut LPG Recovery for second processing train. Includes molecular sieve dehydration, cryogenic LPG recovery and liquids fractionation. Existing Train A dehydration and LPG recovery equipment remains in place.

! Deep Cut LPG Recovery for both processing trains. Includes molecular sieve dehydration, cryogenic LPG recovery and liquids fractionation. Existing train dehydration and LPG recovery equipment is removed.

! Ethane Extraction for both processing trains. Includes molecular sieve dehydration, cryogenic ethane extraction and liquids fractionation. Existing train A dehydration and LPG recovery equipment is removed.

! Each option includes an evaluation of existing plant wide systems such as instrument air, fuel gas, steam generation, control system, etc.


Thermo Design generated basic engineering documents for expansion of existing facilities to increasegas processing capacity from 1.1 bcma to 2.2 bcma with increased production of propane, butane andC5+ liquids. A summary of generated documents by Thermo Design follows:

Process

! Basis of Design, Conceptual Study Report

! Process Sizing Criteria


! Heat and Mass Balances


! P&I Diagram (Process, Utility, Offsite)

! Philosophies (Vent, Relief, Blow Down, Drainage, Operating & Control)

! Process Data Sheet for Equipment, Systems, Packages, Control/Safety Valves

! Process Thermal Calculations

! Flare Load Summary



! Plant Emission

10



! Safety Concept

! ESD Philosophy

! Specification for Climate, Utilities and Units of Measure

! HAZOP / HAZID Study

! SIL Calculation

! Consequence Analysis Study

! Safety Layout

! Area Classification

! Fire Zones & Fire Partitioning

! Passive Fire Protection

! Active Fire Fighting

! Fire & Gas Detection

! Emergency Escape Routing

! Environment Protection / Waste Management Plan

! Constructability Study

Piping / Layout

! Piping Material Specifications


! Equipment Layout (3D)

! Critical Line Study (3D)

! Piping Stress Calculation

! Single Line Pipe Rack Drawings

! Preliminary Material Take Off

! Line List

Fixed Equipment

! Specification / Mechanical Data Sheet / Shell & Tube Heat Exchangers, Cold Heat Exchangers, Pressure Vessels

Rotary Equipment

! Mechanical Data Sheet, Specification for Compressors, Pumps, Utility packages, Gas Turbines

Civil & Structural

! Civil Design Philosophy

! Design Drawings for Underground Service Utilities, Roads & Paving, Earthwork, Drainage, Foundations, Concrete Works

! Loading of Critical Line for Pipe Rack and Supports

! 3-D Model for Steel Structure

! Preliminary Material Take Off for Civil Material, Steel Structure & Concrete Works

11


HVAC

! Design Criteria, Specification, Data Sheet for HVAC

! Duct, Pipe & Instrument Diagrams

! Preliminary Material Take Off for HVAC & Plumbing

Electrical

! Electrical Design Philosophy

! Electrical Load List

! Hazardous Area Classification

! Specification, Sizing and Datasheets for Electrical Equipment

! Load Flow Study

! LV, MV Single Line Diagram

! Emergency Power Single Line


! Substation / Control Room Equipment Arrangement


! Control Philosophy Specification

! Instrumentation Data Sheet & Specification

! PCS, ESD, F&G Specification

! Control Systems Diagram / Logic Diagrams / Cause & Effect Matrix

! Instrument Index

! I/O List & Summary

! SIL Dossier, Test & Calibration Procedure

! Control Building / Technical Equipment Room / Main Cable Route Layout

! Electrical Power & Air Consumption List

P R O J E C T E Q U I P M E N T S U M M A R Y

The engineering documentation was prepared for the process & utility equipment summarized below.

Inlet Reception Facilities ! Slug Catcher

! Slug Accumulators

Gas Dehydration (DRIZO) ! Gas/Glycol Contactor

! Glycol Regeneration

! Filters, Flash/Surge Drums, Exchangers/Strippers

Gas Chilling, LTS, Deethanization ! Gas/Gas Exchanger

! Gas/Liquid Exchanger

! Chiller

! LTS

! De-ethanizer Tower

! Condensers / Reboiler

! Overheads Compressor

12


Propane Refrigeration ! Compressor / Turbine

! Condensers, Economizers, Scrubbers

Power Generation / Distribution & Control System

! MV/LV Switchgear

! UPS

! PCS, ESD, F&G Systems

Heat Medium Supply (Steam & Glycol)

! Packaged Steam Boiler

! Separators, Exchangers

Flare & Drain ! Knock-out Drums

! Liquid Drain Tanks

! Flare Header Network

Instrument Air & Nitrogen Generation

! Packaged I/A Compressors

! Nitrogen Generator / Booster Compressor

! I/A, Utility Air, N2 Receivers

NGL Fractionation ! Depropanizer / Debutanizer Towers

! Condensers, Reboilers, Reflux Drums

13


I N T E G R A T E D G A S T R E A T M E N T P L A N T

T N K - B P

Pokrovka Field, Orenburg Region, Russia


Thermo Design was awarded a contract to design an Integrated Gas Treatment Plant with a nominal inlet gas flow of 450,000,000 m

3/year @ 0.12-0.25 MPag and 10°C.

The contract included the following engineering tasks:

! Engineering Design of the Gas Treatment Plant adequate for getting State Approval of the Project.

! Process: from philosophies to Piping & Instrumentation Diagrams and equipment process datasheets.

! Electrical: from system specification to equipment and load lists. Hazardous area classification drawings and design calculations

! Instrumentation & Controls: from philosophies and system specification to Instrument Index

! Safety Engineering: from conceptual study to HAZID, HAZOP and SIL calcilations.

! Mechanical Engineering: design of stationary equipment – from calculations to datasheets; rotating equipment specifications and selection.

14


P L A N T U N I T S U M M A R Y

! Feed gas compression unit;

! Condensate stabilization/sweetening unit;

! Gas Sweetening Unit;

! Gas Dew point Control & Liquids Fractionation Unit;

! Glycol Regeneration Unit;

! Sulfur Recovery Unit;

! Sulfur Pelletting Unit;

! Pelletized Sulfur Storage and Handling Facilities;

! Nitrogen and Instrument Air Generation Unit;

! Heat Medium System;

! Demineralized Water Treatment Unit;

! Fuel Gas Treatment Unit

Feed gas compression unit

The inlet gas compression systems consist of three 33% capacity Feed Gas Compressor Trains. Thecompressor trains provide three stage compression of the plant feed gas feed stream. The three compression trains operate in parallel. The plant feed gas streams boosted to the operating pressure of the Module AGSMDEA Gas Sweetening. The gas compression trains are designed for 52,000 Nm³/hr total or 17,333 Nm³/hr each at a suction pressure of 0.12 MPag and a discharge pressure of 6.1 MPag.

Condensate stabilization/sweetening unit

The objective of the Condensate Stabilization/Sweetening Unit is to remove H2S from the sour hydrocarbon liquids produced in the compression process so it can be processed in the FractionationUnit. The liquids are also partially stabilized through the removal of ethane and lighter components prior to being fed to the Depropanizer tower.

Gas Sweetening Unit

The objective of the MDEA Sweetening Unit is to remove H2S from the sour natural gas stream from theFeed Gas Compression Unit prior to entering the Hydrocarbon Dew point & Liquid Fractionation Unit. The MDEA Gas Sweetening Unit is a regenerative amine process for the removal of hydrogen sulphide and carbon dioxide from the gas stream. An aqueous solution of MDEA (methyl diethanol amine), at a concentration of 45 weight percent is used to sweeten the raw gas. This solution contains water, intowhich the gases dissolve into the amine solvent, containing the MDEA, with which the acid gases chemically react.

Gas HC Dew point Control & Liquids Fractionation Unit

The objective of the Hydrocarbon Dew point and Liquids Fractionation Unit is to remove heavy hydrocarbons from the natural gas stream to produce a Propane/Butane liquid blend and a C5+condensate stream. The Gas Fractionation Unit utilizes mechanical propane refrigeration to cool the gas stream to -14°C and distillation towers to produce the liquid product streams. Ethane gas producedduring distillation is compressed back to sales gas pipeline pressures. The gas is dehydrated by utilizingethylene glycol.

15


Glycol Regeneration Unit

Water is removed from the natural gas entering the gas chilling equipment using an 80% weight solution of ethylene glycol (EG). The EG solution is sprayed onto the tube sheets of the gas/gas exchanger, gas/liquid exchanger and the gas chiller.

Sulphur Recovery Unit

The objective of the Sulfur Recovery Unit is to convert H2S from the acid gas feed to a liquid sulphurproduct. A three bed Claus Unit is provided to achieve a SOR sulfur recovery of 98.2%. The liquid sulphur product has a purity of 99.95%.

Sulphur Pelletting Unit

The objective of the Unit is to granulate the liquid sulfur and produce the sulphur pallets. The unit process is based on Sandvik technology.

Pelletized Sulphur Storage & Handling Facilities

The objective of the unit is to bag and store the sulphur product.

Nitrogen and Instrument Air Generation Unit

Nitrogen is generated between 95.0% to 99.5% purity, inert gas, for the purposes of fire suppression and utility requirements. The nitrogen system has a design capacity of 10 Nm³/hr at a supply pressure of 1.0Mpag. The Nitrogen generation skid has four sub-systems: inlet air compression and preparation, nitrogen generation via the Generon permeable membrane modules, high pressure nitrogen compression as well as nitrogen storage and distribution

Dry instrument air is supplied for operation of plant instrumentation. The instrument air package has a design capacity of 194 Nm³/hr at a supply pressure of 0.72 MPag. The instrument air unit includes inlet air compression and air drying.

Heat Medium System

Process heating duty is supplied by heat medium fluid supplied at 275°C from the heat medium skid.

Heat medium returns from the plant to the Heat Medium Expansion. The Heat Medium Pumps (two 100% capacity units) take suction from the heat medium heater and circulate the hot oil through the Heat Medium Heater. This heater is a direct-fired heater and has a capacity of 30,830 MJ/hr.

Demineralised Water Treatment Unit

During distillation is compressed back to sales gas pipeline pressures. The gas is dehydrated by utilizing ethylene glycol.


Fuel gas for plant operation will be obtained from the sales gas line during normal plant operation. During plant start-up, fuel gas will be provided by the Client. TDE has included a fuel gas conditioning skid that includes and electric heater, pressure control station and fuel gas scrubber to remove liquids and impurities from the gas stream.

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TDE Corporate Portfolio Rev 1.0 (10-May-09) Turn Key Projects.pdf · Thermo Design was awarded a...

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Transcript of TDE Corporate Portfolio Rev 1.0 (10-May-09) Turn Key Projects.pdf · Thermo Design was awarded a...