WAGL Energy Limited Amazon Energy Engineering

Limited
Project Title

FEED & DED FOR REHABILITATION WORKS AT ESCRAVOS CRUDE

OIL TERMINAL AND IMPORT BERTH PLATFORM (IBP)
Document Title

PROCESS SIMULATIONS REPORT

Document Number: ETRP-ECT-AEL-PRO-RPT-20042

Project Code Facility Description Originator Discipline Code Document Type Sequential Document Number

ETRP ECT AEL PRO RPT 20042

0 2-June-20 Issued for Review R. Renner O. Oniku E. Anuge

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Contractor Company
Rev Date Description Prepared Reviewed
Approval Approval

This document is CONFIDENTIAL and the sole property of the Company. It shall neither be shown to third parties nor used for other purposes than those for which it has
been issued/sent. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited.
DOCUMENT AMENDMENT HISTORY

REV. DATE OF DESCRIPTION OF PAGE AUTHORITY FOR

NO AMENDMENT AMENDMENT AMENDED AMENDMENT

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TABLE OF CONTENTS
1.0 INTRODUCTION 6
1.1 PROJECT BACKGROUND 6
1.2 PROJECT OBJECTIVE 6
2.0 GENERAL 8
2.1 PURPOSE 8
2.2 ABBREVIATIONS AND ACRONYM 8
2.3 TERMS AND DEFINITIONS 8
2.4 INTERNATIONAL REFERENCES, CODES AND STANDARDS 9
2.5 REFERENCES DOCUMENT 9
3.0 FACILITY DESCRIPTION 10
3.1 ENVIRONMENTAL DATA 10
3.2 CRUDE OIL DEHYDRATION UNIT 11
3.3 PRODUCED WATER TREATMENT UNIT 11
3.4 WET CRUDE OIL FROM THIRD PARTY BARGES 12
3.5 CRUDE OIL FROM AEPP INJECTION LINE 12
3.6 OFFSHORE EXPORT PUMPS 12
3.7 FUEL GAS SUPPLY SYSTEM 13
4.0 INPUT DATA 14
4.1 PRODUCED FLUID DATA 14
4.2 CRUDE DEHYDRATION UNIT. 14
4.3 HYPOTHETICAL COMPONENTS 16
4.4 PROCESS DESIGN CONDITIONS 18
4.4.1. Inlet Conditions.......................................................................................................18
4.4.2. Product Specification..............................................................................................18
4.4.3. Offshore Export Pump Parameters.........................................................................19
4.4.4. Computer Software................................................................................................19
5.0 PROCESS SIMULATIONS 20
5.1 PROCESS DESCRIPTION 21
5.2 STEADY STATE SIMULATION RESULTS 21
6.0 HYDRAULIC SIMULATION ANALYSIS 22
6.1 EXECUTIVE SUMMARY 22
6.1.1 Oil Evacuation Pipeline to WAGL Energy Limited Filling Manifold..........................22
7.0 COMPUTER TOOLS 23
7.1 SOFTWARE 23
7.2 BOUNDARY CONDITIONS 23
7.2.1 Inlet/Arrival Conditions and Flow rate.....................................................................23

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7.2.2 Pipeline Arrival Pressure........................................................................................23

7.3 FLUID COMPOSITIONS 24
7.3.1 Oil Compositions....................................................................................................24
7.3.2 Psuedo Components Properties.............................................................................25
7.3.3 Gas composition.....................................................................................................26
8.0 METHODOLOGY 27
8.1 FLUID PHASE ENVELOP 28
9.0 STEADY STATE SIMULATION 29
9.1 EQUATION OF STATE THEOREM 29
9.2 SIMULATION CRITERIA 29
9.3 EROSION VELOCITY CRITERIA 29
10.0 OIL PIPELINE DESIGN DATA 30
10.1 THERMAL CONDUCTIVITY 30
10.2 PRESSURE DROP CRITERIA 30
11.0 CALCULATION RESULTS ANALYSIS 31
11.1 RESULTS 31
12.0 OIL PIPELINE SIZING RESULTS SUMMARY 32
12.1 DISCUSSION OF RESULTS 33
12.2 Pressure Profile Sensitivities Plots 33

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LIST OF FIGURES
FIGURE 1-1: NNPC - NPSC ESCRAVOS TERMINAL................................................................................7
Figure 8-1: AEPP TIE-IN – WAGL TRANSFER LINES AND MANIFOLD.................................................27
Figure 8-2: AEPP TIE-IN – WAGL PIPE LINE PHASE ENVELOP............................................................28
Figure 12-1: AEPP Tie-In – WAGL Transfer Lines/ Manifold Sensitivities.................................................33

LIST OF TABLES
Table 4.1: Wet Crude Oil Composition...................................................................................................... 16
Table 4.2 Wet Crude Oil Hypothetical Component....................................................................................18
Table 7.1 Boundary Conditions................................................................................................................. 23
Table 7.2: Crude Oil Boundary Conditions............................................................................................... 25
Table 7.3: Hypo Component Properties (C30+)......................................................................................... 25
Table 7.4: Fuel Gas Boundary Condition................................................................................................... 26
Table 7.5: Gas Fluid Properties................................................................................................................. 26
Table 10.1: Gas and Oil Bulk Pipeline Design Data...................................................................................30
Table 10.2: Pipeline Thermal Conductivity................................................................................................30
Table 12.1: Pipeline Sensitivities Results.................................................................................................. 32

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1.0 INTRODUCTION

1.1 Project Background

WAGL Energy Limited, a Joint Venture Company between NNPC and Sahara Energy
Group have taken over its crude oil import facilities (the Import Berth Platform (IBP)
and the onshore terminal) at Escravos, to operate them at their installed design
capacities. The crude oil import facilities comprise of an SBM, subsea pipeline, the
IBP and onshore facilities at Escravos Tank Farm.

The onshore facilities (Escravos Tank Farm) are central to the delivery of crude oil to
both the Warri and Kaduna Refineries via the 24”x 62 km Escravos to Warri pipeline
and 16”x 735 km Warri to Kaduna pipelines. Due to the current state of the onshore
facilities, crude oil is pumped to Warri using the facilities of Chevron-Texaco in the
adjacent property.

In order to ensure regular crude oil supply to the aforementioned refineries, there is a
need to perform the following; (i) completely rehabilitate these existing facilities (i.e.
IBP and Escravos tank Farm) and (ii) Plan for a second pipeline from Escravos to
Warri. This flexibility is required for so many reasons some of which include the
following;

 Aging of pipeline asset: Pipeline is over 30 years old (and past its design life) and
its integrity can no longer be assured

 Vandalism and sabotage: Activities of vandals on the ROW

To achieve the overarching objective of rehabilitating the existing facilities, WAGL

Energy Ltd has secured the services of Amazon Energy Engineering Limited to
execute FEED/ DED.

1.2 Project Objective

The objective of the project is to rehabilitate and upgrade the NNPC - NPSC Escravos
Terminal (Onshore) and IBP (Offshore) facilities to full functionality while meeting
world-class standard such that the facility will be a reference for foreign and local
customers, with operational integrity to meet customers’ expectations.

The facilities shall enable WAGL Energy Ltd achieve the following strategic
objectives:

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 Receive and store imported crude oil;

 Receive wet crude oil from third party via barges, process and store the crude oil.

 Export crude oil to local and international Customers; and

 Operate the facility at optimum capacity.

FIGURE 1-1: NNPC - NPSC ESCRAVOS TERMINAL

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2.0 GENERAL

2.1 Purpose
The purpose of this document is to provide the approach to simulations carried out in
other obtain the steady station operating conditions for the new WAGL Energy Limited
process equipment, piping and pipeline systems. The results of the simulations studies
carried out are used as input for the sizing and rating of all the process equipment,
piping and pipeline. The simulation studies carried out gives rise to the heat and
material balance

2.2 Abbreviations and Acronym

AEEL Amazon Energy Engineering Limited

AEPP Amukpe - Escravos Pipeline
BS&W Basic Sediment and Water
CNL Chevron Nigeria Limited
CPI Corrugated Plate Interceptor
DED Detailed Engineering Design
DPR Department of Petroleum Resources
FEED Front End Engineering Design
IBP Import Berth Platform
LACT Lease Automatic Custody Transfer
NNPC Nigerian National Petroleum Company
NPS Nominal Pipe Size
NPSC Nigerian Pipelines and Storage Company
ROW Right of Way
SBM Single Buoy Mooring
SOW Scope of Work
WRPC Warri Refinery and Petrochemical

2.3 Terms and Definitions

Terms Meaning
Company WAGL Energy Limited

Contractor Amazon Energy Engineering Limited

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Procedure Specified way to carry out an activity or a process

Process Set of interrelated or interacting activities which transforms inputs

into outputs.
Project FEED and DED for Rehabilitation Works at Escravos crude oil
terminal and import berth platform (IBP)

Shall Indicates mandatory requirement.

Should Indicates preferred course of action.

Specification Document stating requirements

2.4 International References, Codes and Standards

These are the various COMPANY requirements, inputs, procedures and specifications,
design basis/philosophy which are part of the contract or are required for the execution
of the project, details are as follows:

Document Number Document Title

API 14E Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems

API 610 Centrifugal Pumps for Petroleum, Heavy Duty Chemical and
Gas Industry Services

API 650 Welded Tank for Oil Storage

2.5 References Document

Document Number Document Title
CONT/DED/wagl/SAVO/2019/01 Scope of Work

ETRP-ECT-AEL-PRO-PFD-20006 PFD Crude Oil Dehydration Unit

ETRP-ECT-AEL-PRO-PFD-20007 PFD Produced Water Treatment

ETRP-ECT-AEL-PRO-PFD-20059 PFD-AEPP Crude Oil Transfer System

ETRP-ECT-AEL-PRO-PFD-20060 PFD-Third Party Crude Oil Transfer System

ETRP-ECT-AEL-PRO-PFD-20003 PFD-Transfer Lines System

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ETRP-ECT-AEL-PRO-PFD-20061 PFD Offshore Export Pipeline

AEPP-AU-020-RPT-00-00002 Hydraulic Analysis

3.0 FACILITY DESCRIPTION

3.1 Environmental data

The average weather conditions at site are given below:

Climate The climate is tropical with a marine-salty environment

(Niger River delta area)
Air: Absolute minimum temperature: 16°C
Absolute maximum temperature: 36°C
Design temperature (for indoor and Dry bulb temperature: 34°C
outdoor) Wet bulb temperature: 28°C
Design temp. for engines/turbines/air 36° C
coolers
Relative humidity 90 to 95% Relative humidity 90 to 95%
Maximum humidity 99% Maximum humidity 99%
Fine sand Present in the atmosphere during a 2-months
“Harmattan” (Saharan wind) period.
Rainfall For 60 minutes: 92 mm/h
For 30 minutes: 140 mm/h
For 15 minutes: 160 mm/h
Heavy rain: storm presence
Daylight 10-12 hours/day of daylight over 12 months (maximum
is in June).
Wind The highest mean wind velocity at 10 m above ground
level is 75 km/h
Lightning High concentration of direct lightning phenomena
during seasonal storms
Altitude Sea level
Earthquake None

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3.2 Crude Oil Dehydration Unit

The dehydration unit has been proposed to be installed in the facility, this is to ensure
that the wet crude oil from third party can be treated to meet export specification.
This unit takes from the dedicated wet crude oil storage tank using the existing slop
pump P-102A/B to charge the wet crude oil to the skidded heater treater where
emulsion in the wet crude oil is to be broken down to separate phases, oil and water.
The water is removed and sent for treatment. The heater treater shall be a vendor
package and shall be designed to produce a crude oil with less than 0.5% BS&W as
required by specification. All required information/data shall be available to the vendor
for proper design. The dehydrated crude oil is then stored in a storage tank for export.

3.3 Produced Water treatment Unit

This unit has a sole purpose of treating the effluent water from the crude oil dehydration
unit in order to meet disposal requirement (DPR regulation of not more than 50 mg/l oil
in water). This will be achieved through proper treatment with the following facilities
installed in the facility.
• Surge tank
• Corrugated plate interceptor (CPI).
• Induced Static Floatation Unit (ISF).
The produced water from the crude oil dehydration unit is injected with an oxygen
scavenger, mixed inline using a static mixer and then sent to a surge tank. Carried over
crude oil in the surge tank is gradually removed using a special floating skimmer and
sent to the sump. The water from the surge tank shall be pumped to a corrugated plate
interceptor (CPI) and induced static flotation (ISF) units for further treatment. These
units shall be vendor packages.
The produced water from the ISF unit is expected to meet disposal specification before
it is discharged to the water body.
Fuel gas has been used as blanketing gas and to keep the pressure within the surge
tank constant during inflow and pump out.

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3.4 Wet Crude Oil from Third Party Barges

WAGL Energy Limited has indicated that it intends to receive wet crude oil from third
party barges into the terminal; for this to be fit for export, it will be dehydrated and the
produced water treated and disposed. The NPSC Jetty is to be used as the berthing
point for the barges; a transfer line shall be provided in order to transfer the crude oil
from the jetty area to the terminal, a chemical injection package has been proposed for
the line. It is expected that the barge will have transfer pumps capable of transferring
the crude oil to the terminal receiving tank. The incoming transfer line shall be tied into
the terminal to ensure that the crude oil can be received into the dedicated tank as
stated above. A LACT unit has also been proposed, this will be used to measure the
crude oil prior to its arrival at the terminal.

3.5 Crude Oil from AEPP Injection line

Based on the project intent, crude oil is expected to come into the terminal from AEPP
injection line; the line is assumed to be 3km. A dedicated chemical injection package
has been proposed for the line. The crude oil pressure at the tie-in point should be
sufficient to deliver the crude oil into the terminal. The incoming line shall be tied into
the terminal to ensure that the crude oil can be received into any of the tanks as it is the
case for the foreign and local crude oil. A LACT unit has been proposed, this will be
used to measure the crude oil prior to tie-in within the terminal.

3.6 Offshore Export Pumps

A new set of pumps have been proposed for the dedicated function of exporting crude
oil from the Escravos terminal to IBP. These pumps have been designed to operate in a
3x50% mode and adequate tie-in points have been provided for the suction and the
discharge headers.
The terminal export header shall serve as the offshore export pump suction, for the
purpose of export to the IBP, the mainline pump shall be in the shutdown mode; valve
interlock system has been proposed to ensure that flow is directed correctly.
The local crude import pipeline from CNL shall be utilised as the export line to the IBP
via NPSC tie–in manifold located in CNL. The pump discharge MOV shall be
interlocked with the existing adjacent MOV on the filling manifold as shown in the
relevant project drawings to prevent flow in the wrong direction and to ensure the right
MOV is in open/ close position. At the tie-in manifold, valves shall be appropriately lined

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up to achieve flow to the IBP.

3.7 Fuel Gas Supply System

A supply of treated natural gas from the CNL facility comes into the NPSC Escravos
terminal to feed the gas users in the facility; these includes the turbo-mainline pumps,
the offshore export pumps turbo generators, the new heater treater (Crude oil
dehydration unit), the new surge tank and induced static flotation vessel (Produced
water treatment unit) as shown in the project drawings.
The fuel gas is also used as instrument gas for various users in the new units.
The fuel gas system is comprised of:
 Fuel gas filter (F-112 A/B) to remove liquids.
 A gas heater (H-101) to elevate the temperature of the incoming fuel gas.
 A 3” by 1km pipeline from the fuel gas source (CNL Facility) to the fuel gas users
(NPSC Escravos Terminal)

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4.0 INPUT DATA

4.1 Produced Fluid Data

Fluid properties have been prepared based on the Excravos petroleum assay
available in the Aspen Technology (Hysys) Simulation Software as no fluid data
was made available by the client. The produced fluid composition was
characterized using Hysys Simulation Software. The result (see section 4.2 for
details) was used as input for the process simulation studies carried out on the
WAGL Energy Limited facilities.

4.2 Crude Dehydration Unit.

S/N Component Mole fraction

1 Propane 0.0001
2 i-Butane 0.0011
3 n-Butane 0.0022
4 i-Pentane 0.0084
5 n-Pentane 0.0022
6 Cyclopentane 0.0003
7 H2O 0.5987
8 40-50C* 0.0058
9 50-60C* 0.0071
10 60-70C* 0.0082
11 70-80C* 0.0093
12 80-90C* 0.0080
13 90-100C* 0.0089
14 100-110C* 0.0097
15 110-120C* 0.0105
16 120-130C* 0.0110
17 130-140C* 0.0113
18 140-150C* 0.0116
19 150-160C* 0.0119
20 160-170C* 0.0120

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S/N Component Mole fraction

21 170-180C* 0.0120
22 180-190C* 0.0120
23 190-200C* 0.0119
24 200-210C* 0.0116
25 210-220C* 0.0114
26 220-230C* 0.0112
27 230-240C* 0.0110
28 240-250C* 0.0107
29 250-260C* 0.0105
30 260-270C* 0.0107
31 270-280C* 0.0105
32 280-290C* 0.0102
33 290-300C* 0.0091
34 300-310C* 0.0100
35 310-320C* 0.0089
36 320-330C* 0.0084
37 330-340C* 0.0078
38 340-350C* 0.0072
39 350-360C* 0.0066
40 360-370C* 0.0061
41 370-380C* 0.0057
42 380-390C* 0.0052
43 390-400C* 0.0048
44 400-410C* 0.0044
45 410-420C* 0.0040
46 420-430C* 0.0037
47 430-440C* 0.0035
48 440-450C* 0.0032
49 450-460C* 0.0027
50 460-480C* 0.0045
51 480-500C* 0.0036
52 500-520C* 0.0029

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S/N Component Mole fraction

53 520-540C* 0.0025
54 540-560C* 0.0020
55 560-580C* 0.0017
56 580-600C* 0.0016
57 600-625C* 0.0018
58 625-650C* 0.0016
59 650-675C* 0.0012
60 675-700C* 0.0009
61 700-725C* 0.0006
62 725-750C* 0.0004
63 750-775C* 0.0003
64 775-800C* 0.0002
65 800-825C* 0.0002
66 825-850C* 0.0004
67 850+C* 0.0001
Table 4.1: Wet Crude Oil Composition

4.3 Hypothetical Components

Description Normal Boiling Point Molecular Weight Ideal Liquid Density

C Kg/kmol Kg/m3
NBP (36-40) 40.00 73.77 635.40
NBP (40-50) 50.00 77.81 653.80
NBP (50-60) 60.00 81.75 676.50
NBP (60-70) 70.00 85.85 694.80
NBP (70-80) 80.00 90.21 708.10
NBP (80-90) 90.00 95.34 711.40
NBP (90-100) 100.00 100.70 714.00
NBP (100-110) 110.00 106.30 716.60
NBP (110-120) 120.00 111.80 742.10
NBP (120-130) 130 117.40 732.60
NBP (130-140) 140 123.20 741.10
NBP (140-150) 150 129.10 749.50
NBP (150-160) 160 135.10 759.70

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NBP (150-170) 170 141.40 767.90

NBP (170-180) 180 147.90 775.80
NBP (180-190) 190 154.60 783.50
NBP (190-200) 200 161.60 790.90
NBP (200-210) 210 168.80 798.10
NBP (210-220) 220 176.30 805.00
NBP (220-230) 230 184.00 811.70
NBP (230-240) 240 192.10 818.10
NBP (240-250) 250 200.50 824.30
NBP (250-260) 260 209.80 827.80
NBP (260-270) 270 218.80 833.70
NBP (270-280) 280 228.00 839.50
NBP (280-290) 290 237.60 845.20
NBP (290-300) 300 247.30 850.80
NBP (300-310) 310 257.40 856.30
NBP (310-320) 320 267.60 861.70
NBP (320-330) 330 277.90 866.90
NBP (330-340) 340 288.40 872.10
NBP (340-350) 350 298.90 877.20
NBP (350-360) 360 309.30 882.10
NBP (360-370) 370 319.60 887.00
NBP (370-380) 380 329.70 891.70
NBP (380-390) 390 340.90 893.90
NBP (390-400) 400 353.30 898.50
NBP (400-410) 410 367.10 903.10
NBP (410-420) 420 380.80 907.60
NBP (430-430) 430 394.30 912.20
NBP (430-440) 440 407.60 916.70
NBP (440-450) 450 420.70 921.20
NBP (450-460) 460 433.70 925.70
NBP (460-480) 480 461.30 932.30
NBP (480-500) 500 486.70 941.10
NBP (500-520) 520 512.20 949.90
NBP (520-540) 540 538.00 958.50
NBP (540-560) 560 564.70 967.00
NBP (560-580) 580 592.60 975.40
NBP (580-600) 600 622.20 983.80

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NBP (600-625) 625 667.60 990.30

NBP (625-650) 650 718.00 996.90
NBP (650-675) 675 769.90 1006.00
NBP (675-700) 700 827.90 1015.00
NBP (700-725) 725 911.10 1019.00
NBP (725-750) 750 1002.00 1023.00
NBP (750-775) 775 1093.00 1030.00
NBP (775-800) 800 1190.00 1036.00
NBP (800-825) 825 1292.00 1043.00
NBP (825-850) 850 1398.00 1049.00
850+ 900 1621.00 1062.00
Table 4.2 Wet Crude Oil Hypothetical Component

4.4 Process Design Conditions

4.4.1. Inlet Conditions

The feed condition of the wet crude into the crude dehydration unit
Inlet temperature 16oC (lowest ambient)
Inlet Pressure 3.2 bar.a
Flow rate 200 m3/h (feed pump capacity)
Density 869.6 kg/m3
Molecular weight 92.48
Viscosity 6.999 cP

Produced water inlet temperature 50oC

Inlet pressure 3.2 bar.a
Flow rate 20 m3/h
Density 988 kg/m3

4.4.2. Product Specification

Water in Crude Oil < 0.5 % by Volume (maximum)
Dry Crude Oil SG 0.8284
Dry Crude Kinematic Viscosity 2.634 cSt
Dry Crude Oil Delivery Pressure 4.48 barg
Product Water Oil Content 1 % by volume
Produced Water Delivery Pressure 5.24 barg

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Produced Water Delivery rate 19.86 m3/hr

4.4.3. Offshore Export Pump Parameters

Inlet temperature 30oC
Inlet pressure 4.9 bar.a
Flow rate 1530 m3/h
Density 850 kg/m3
Molecular weight 203.3
Viscosity 2.18 cP

4.4.4. Computer Software

The computer software which has been used for simulations are
a. HYSYS version 10 by Aspen Technology Inc
b. Pipesim Steady Simulation Simulator version 2019 for pipelines
by schlumberger

5.0 PROCESS SIMULATIONS

The process modelling of the proposed crude oil dehydration unit and the produced

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water systems in the WAGL Energy Limited have been carried out, using Aspen Hysys
version 10.0 Two different simulations models were developed that describes the
maximum limit of the operating envelope of the desired equipment items in the facility.
The steady state simulation models are
1. Crude oil dehydration system
2. Produced water system

 Heater Treater (V-2601)

 Dehydrated Crude Oil discharge pump (P-2601)
 Produced Water Discharge Pump (P-2602)
 Surge Tank (T-2902)
 Corrugated Plate interceptor (CPI, (V-2901)
 CPI feed Pump (P-2902 A/B)
 Induced Static Flotation Unit (V-2902)
 Induced static Flotation Unit recycle Pump (P-2904 A/B)
 Off-shore disposal Pump (P -2905)
 Flocculant Tank (T-2903)
 Flocculent Pump (P-2903)
 Oxygen Scavenger Tank (T-2901)
 Oxygen Scavenger Pump (P-2901)

Produced water will be separated from oily water discharge from the crude dehydrating
unit. The water outlet from the crude dehydrating unit will feed directly to three-stage
oily water treatment units. The first stage of separation is the surge tank, the effluent
from the surge tank is feed to the CPI unit which will have the capability to remove more
of the oil globules in water. The CPI unit contains parallel plate interceptors which will
enhance small oil globules removal. The very small oil particles that cannot be removed
by the skimmer in the surge tank and CPI unit will be removed by the gas floatation unit.
The oil content in the final effluent shall be less than 30 ppm, which is within DPR
environmental water disposal limit.

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5.1 Process Description

The computer model for the cases considered includes the new oily water treatment
units, as follows: (see also section 2.5) for Process Flow Scheme Doc No for details
1. ETRP-ECT-AEL-PRO-PFD-20006-Crude Dehydration Unit
2. ETRP-ECT-AEL-PRO-PFD-20007-Produced Water Unit

5.2 Steady State Simulation Results

A. Produced Water Hysys Process Flow Diagram

B.

C. HMB

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6.0 HYDRAULIC SIMULATION ANALYSIS

6.1 Executive Summary

Hydraulic simulation was conducted for three units

1. The Proposed pipeline from AEEP crude oil
2. The fuel gas supply pipeline from CNL facility to NPSC Escravos Terminal
3. The new offshore export pumps

The proposed pipelines were analysed based on boundary conditions data obtained
from the facility owner (WAGL Energy Limited). The main parameters studied were the
diameter of the pipeline, pressure and velocity, the results are summarized as follows:

6.1.1 Oil Evacuation Pipeline to WAGL Energy Limited Filling Manifold

Following are results from the analysed scenarios for the proposed oil evacuation line
The proposed 12” x 3 km pipeline for the de-energized fluid evacuation is adequate
and fit for purpose; as this option meets the minimum fluid velocity requirement of 3 ft/s
(1 m/s) in line with global practice standard and maximum fluid velocity of 5 m/s
Refer to section 12, page 27 of 28, average velocity in the 12-inch pipeline is 4.12 m/s.
The minimum arrival pressure at WAGL Energy Limited Filling Manifold is 23 .75 barg,
it is recommended that a pressure letdown be considered to bring down the pressure to
3 barg

6.1.2 Fuel Gas Supply system

The Results are

6.1.3 Offshore Export Pumps

The Results are analyzed

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7.0 COMPUTER TOOLS

7.1 Software
PIPESIM steady simulation software has the capability to establish the flow rates
transported via any infield and bulk pipelines configuration, if both boundary pressure
and physical properties of the fluid were available such as hydrocarbon composition for
multiphase/associated pipelines.
PIPSIM simulator version 2019 was employed to estimate the hydrocarbon mass rates
based on the characterized compositions obtained from ASPEN HYSYS/MULTIFLASH
fluid simulation package and the provided boundary conditions mentioned in section 7.2
The ‘’Peng Robinson’’ Equation of state was selected to perform the flash calculation
with ‘’Property package EOS’’ method option was used for the enthalpy estimation for
the thermodynamic and physical properties both in ASPEN HYSYS/MULTIFLASH and
PIPESIM multiphase steady state software

7.2 Boundary Conditions

7.2.1 Inlet/Arrival Conditions and Flow rate

Inlet Arrival
Arrival Pipeline
S/N Source Gas Oil Operating Pressure
Temperature
  Name Flowrate Flowrate Pressure. (Oil
(Oil) Pipeline)
  MMSCFD Bopd Barg Barg DegC
Maximu Maximu
  Maximum Minimum
m m
1 AEPP N/A 160,000 33 23.75 21
Third Party -
2 Wet Crude N/A N/A N/A
Oil
Fuel Gas 1 N/A
3
from CNL
Table 7.3 Boundary Conditions

7.2.2 Pipeline Arrival Pressure

AEPP to WAGL Energy Facility

Oil Pipeline Arrival Pressure @ filling manifold metering custody transfer unit = 4.01325
bar minimum

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Mole fraction
S/N Compositions (%)
CNL Fuel Gas Supply to Escravos
  Hydrogen 0.0000
Facility 1 H2S 0.0000
Fuel gas supply 2 CO2 0.0000 Pipeline Arrival
Pressure at 3 Nitrogen 0.0000 each consumer unit =
4 Methane 0.0000
XXXXX
5 Ethane 0.0008
6 Propane 0.0102
Offshore Export 7 i-Butane 0.0126 Pumps
Oil Pipeline 8 n-Butane 0.0328 Arrival Pressure at the
9 22-Mpropane 0.0001
IBP Platform = XXXXX
10 i-Pentane 0.0377
11 n-Pentane 0.0435
12 n-Hexane 0.0903
13 Mcyclopentan 0.034
14 Benzene 0.0111
7.3 Fluid 15 Cyclohexane 0.0408 Compositions
16 n-Heptane 0.0812
7.3.1 Oil 17 Mcyclohexane 0.0719 Compositions
The fluid 18 Toluene 0.0301 composition data for the
single-phase 19 n-Octane 0.0927 liquid as provided by
20 E-Benzene 0.0072
client is given below, the GOR and
21 m-Xylene 0.029
GCR shall be 22 o-Xylene 0.0081 calculated/estimated
with a process 23 n-Nonane 0.0589 simulator
24 124-MBenzene 0.0099
25 n-Decane 0.0586
26 n-C11 0.0456
27 n-C12 0.0345
28 n-C13 0.0289
29 n-C14 0.0229
30 n-C15 0.0231
31 n-C16 0.0156
32 n-C17 0.0114
33 n-C18 0.0106
34 n-C19 0.0077
35 n-C20 0.006
36 n-C21 0.0051
37 n-C22 0.0041
38 n-C23 0.0035
39 n-C24 0.003
40 n-C25 0.0026
41 n-C26 0.0022
42 n-C27 0.002
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44 n-C29 0.0016Page 24 of 33
45 n-C30 0.0014
46 C30+ 0.005
PROCESS SIMULATIONS REPORT REV A

Table 7.4: Crude Oil Boundary Conditions

7.3.2 Psuedo Components Properties

Crude Oil Properties
Density 738 kg/m3
Viscosity 0.899  
Molecular Weight (30+) 576  kg/kmol
Density (30+) 931 kg/m3
Sampling Temp 40  degC
Sampling Pressure 751 Psig
Table 7.5: Hypo Component Properties (C30+)

7.3.3 Gas composition

Crude Oil Properties

Nitrogen 0.0096

Methane 0.9042

CO2 0.0174

Ethane 0.0627

Propane 0.0049

i-Butane 0.0004
n-Butane 0.0004

i-Pentane 0.0001

n-Pentane 0.0001

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C7plus* 0.0001

H2O 0.0001

Table 7.6: Fuel Gas Boundary Condition

Mass Density 12.1671 kg/m3

Viscosity 0.0117 cP
Molecular Weight 17.7171
C7plus* Molecular Weight 92.00
C7plus* Density 650 kg/m3
Table 7.7: Gas Fluid Properties

8.0 METHODOLOGY

Single pipeline segment was setup using steady state simulation tool - Pipesim
version 2019. A burial depth of 1 m was adopted, the inlet node represents the
pipeline tie-in source with an operating condition of
a) Pressure: 33 barg
b) Temperature: 30 Deg
A flat elevation of with no undulations was adopted, a typical Niger Delta terrain.
The arrival condition of pressure and temperature was unset. Pipesim 2019 was
to determine the arrival operating conditions at the transfer lines and manifolds,
by varying a sensitivity of pipeline ID for 10, 12 and 16 inches. The determining
or monitoring pipeline parameter are
a) Pipeline mean fluid velocity
b) Pipeline erosional velocity ratio
The figure below shows the pipeline segment setup in pipesim 2019

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Figure 8-2: AEPP TIE-IN – WAGL TRANSFER LINES AND MANIFOLD

8.1 Fluid Phase Envelop

The plot shown in figure 3 is the phase envelope for the proposed Oil evacuation
pipeline, it can be seen that the plot shows a two-phase region, which confirms the
presence of trace gas in the fluid.

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AEPP-WAGL OIL PIPELINE PHASE ENVELOPE PLOT

40
Dew point_curve
35 Bubble point_curve
Critical Point

30
Pressure (barg)

25

20

15

10

0
0 50 100 150 200 250 300 350 400
Temperature (deg. C)
Figure 8-3: AEPP TIE-IN – WAGL PIPE LINE PHASE ENVELOP

9.0 STEADY STATE SIMULATION

9.1 Equation of State Theorem

For steady state simulation, the correlations for both vertical and horizontal pipes were
selected, Beggs and Bill revised and Hagedorn brown, Peng Robison Equation of state

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(EOS) was selected for the fluid simulation package.

The boundary conditions, mass rate (flowrates), temperature and inlet pressure at
source point (AEPP Tie-in) were defined in PIPESIM, Then the multiphase simulator
was queried to predict the required outlet pressure and temperature at the manifold, the
air temperature and other properties specified as outer condition of the pipeline

9.2 Simulation Criteria

The following criteria were considered during the simulation analysis:
Calculated pressure drops and maximum /minimum velocity, this include superficial gas
velocity and liquid velocity profile for single phase flow and multiphase flow.

9.3 Erosion Velocity Criteria

Flowlines, production manifolds, process headers and other lines transporting
multiphase fluid is primarily size on the basis of flow velocity
Erosion at pipe wall or at pipe bend can occur due to high fluid velocities or if the
pressure drop occurs significantly in pipeline, this could happen severely, if solid
particles are present due to corrosive components. The erosion factor, c has been
defined in API RP 14E, Ref 1.4[2], page 25, and section 2.5
The erosive velocity is written in the following form:

Where Ve= Fluid erosional velocity, ft/s

Mixed phase density at flowing temperature and pressure conditions, Ibs/ft^3

For solid free, C= 100, for continuous service,
C= 125 intermittent service

10.0 OIL PIPELINE DESIGN DATA

The following sizing data were used to perform the multiphase and wet gas infield and bulk line size
Corrosion Design
Sizes Units Description
Allowance Pressure/Temp
mm mm mm   mm barg/degC
ND Wall
OD ID Thickness Oil Pipeline
12 304.80 303.22 20.07 3 51.1/38

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Table 10.8: Gas and Oil Bulk Pipeline Design Data

10.1 THERMAL CONDUCTIVITY

Infield/Pipeline Data
  Density Capacity Conductivity
Units kg/m3 J/kgoC w/moC
Carbon Steel 7850 500 50
Soil Layer 1922 900 0.775
Absolute Roughness 20-50 micron
Table 10.9: Pipeline Thermal Conductivity

10.2 PRESSURE DROP CRITERIA

The general pressure drop equation is given below:

The above means the pressure drop in a given pipe segment is inversely proportional to
the pipe diameter; this means the smaller the pipe size the higher the pressure drop.
This principle is applied in the simulation study cases for the crude oil Pipelines

11.0 CALCULATION RESULTS ANALYSIS

11.1 RESULTS
Three (3) main simulations runs in PIPSIM and the results were based on both the
minimum/maximum velocity criteria as referenced on the global standard. The main
parameter studied is the pipeline diameter and using velocity as the judgment criteria.
The outlet pressure at the arrival manifold was calculated by PIPSIM. The results of the
calculated pressures along the pipeline and the velocity profile has calculated by the

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simulator is show below.

The plots show both the pressure profile and velocity profile. The velocity profile is
compared with the global standard and the judgment is based on the acceptable
minimum velocity.
Velocity criteria: Minimum =1 m/s, Maximum = 5 m/s

12.0 OIL PIPELINE SIZING RESULTS SUMMARY

  CASE 1
S/ Size
Pipeline Distance (m) Pressure (barg) Temperature (Deg) Mean Velocity (m/s) EVR
N (Inches)
1 10 Pipeline 0 33.00 32.22 6.18 1.37
2 10 Pipeline 333 30.35 32.10 6.18 1.37
3 10 Pipeline 667 27.69 31.99 6.18 1.37
4 10 Pipeline 1000 25.04 31.88 6.18 1.37
5 10 Pipeline 1333 22.38 31.77 6.18 1.37
6 10 Pipeline 1667 19.73 31.67 6.18 1.37
7 10 Pipeline 2000 17.07 31.57 6.19 1.37

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8 10 Pipeline 2333 14.42 31.47 6.19 1.37

9 10 Pipeline 2667 11.76 31.38 6.19 1.37
10 10 Pipeline 3000 9.10 31.29 6.19 1.37
  CASE 2
S/ Sizes
Pipeline Distance (m) Pressure (barg) Temperature (Deg) Mean Velocity(m/s) EVR
N (Inches)
1 12 Pipeline 0 33.00 32.22 4.12 0.91
2 12 Pipeline 333 32.06 31.97 4.12 0.91
3 12 Pipeline 667 31.11 31.73 4.12 0.91
4 12 Pipeline 1000 30.17 31.50 4.12 0.91
5 12 Pipeline 1333 29.23 31.28 4.12 0.91
6 12 Pipeline 1667 28.28 31.07 4.12 0.91
7 12 Pipeline 2000 27.34 30.87 4.12 0.91
8 12 Pipeline 2333 26.39 30.67 4.12 0.91
9 12 Pipeline 2667 25.45 30.49 4.12 0.91
10 12 Pipeline 3000 24.51 30.31 4.12 0.91
  CASE 3
S/ Sizes
Pipeline Distance (m) Pressure (barg) Temperature (Deg) Mean Velocity(m/s) EVR
N (Inches)
1 16 Pipeline 0 33.00 32.22 2.61 0.58
2 16 Pipeline 333 32.70 31.87 2.61 0.58
3 16 Pipeline 667 32.41 31.54 2.61 0.58
4 16 Pipeline 1000 32.11 31.22 2.61 0.58
5 16 Pipeline 1333 31.81 30.92 2.61 0.58
6 16 Pipeline 1667 31.51 30.63 2.61 0.58
7 16 Pipeline 2000 31.22 30.36 2.61 0.58
8 16 Pipeline 2333 30.92 30.10 2.61 0.58
9 16 Pipeline 2667 30.62 29.86 2.60 0.58
10 16 Pipeline 3000 30.33 29.63 2.60 0.58
Table 12.10: Pipeline Sensitivities Results

12.1 Discussion of Results

The above table shows how the pipeline pressure drops along the entire 3-kilometre
pipeline from the tie-in point to the arrival point before the latch unit. The results
demonstrate the pressure drop equation which says that pressure drop is inversely
proportional the fifth power of the pipe diameter.
From the above three (3) scenarios, the following were observed
Scenario 1: There is sharp pressure drop and the calculated mean velocity along the
pipeline is exceeds the velocity limit of 5 m/s and also the erosional velocity ratio (EVR)
is greater than the acceptable limit of 1, when scenario 1 is not fit for purpose

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Scenario 2: The calculated mean velocity along the pipeline is within the acceptable
velocity limit of 1-5 m/s and erosional velocity limit of < 1, the scenario is the best
scenario for the study
Scenario 3: Although the calculated mean velocity is within the acceptable limit of 1-5
m/s, with an EVR <1, this pipeline is not selected due to CAPEX

12.2 Pressure Profile Sensitivities Plots

AEPP-WAGL Pipeline Pressure Profile Sensitivities

35

30

25
Inlet Pressure (Barg)

20

15

10 10 In
12 In
16 In
5
0 500 1000 1500 2000 2500 3000
Total Distance (m)
Figure 12-4: AEPP Tie-In – WAGL Transfer Lines/ Manifold Sensitivities

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