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REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

TRAINING PROGRAMME AT DELTAAFRIK ENGINEERING LIMITED LAGOS.

Technical Report · September 2019

DOI: 10.13140/RG.2.2.34268.72329

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REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE
SCHEME

(SIWES) TRAINING PROGRAMME

(April 8th, 2019 – October 7th, 2019)

Held at

DELTAAFRIK ENGINEERING LIMITED

LAGOS, NIGERIA.

BY

OMOARUKHE, FREDRICK OLUWATOBI

15/30GM052

CHEMICAL ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING AND TECHNOLOGY

UNIVERSITY OF ILORIN
 CERTIFICATION

This is to certify that OMOARUKHE FREDRICK OLUWATOBI, with matriculation number

15/30GM052 of the department of Chemical Engineering, University Of Ilorin has satisfactorily
completed the six (6) months Student Industrial Work Experience Scheme (SIWES) with
DeltaAfrik Engineering Ltd, situated at Bay Atlantic Tower, 4 Freedom Road, Lekki, Lagos.

....................................................... …………………………………

Student Date

....................................................... ………………………………....

Institution-based Supervisor Date

………………………………… …………………………………

Industry based Supervisor Date

OMOARUKHE FREDRICK 2
 ACKNOWLEDGEMENT

My gratitude goes first to GOD Almighty for his Strength that was made perfect in my weakness
during the period of my training.

I am indeed grateful to the school authority and SIWES for giving me this platform to acquire
practical knowledge in the field of my study. I also thank my institution supervisor, Mr Victor
Obasa for taking time out to check on my progress in the industry and Engr. Amoloye, my SIWES
coordinator for His supervision and great administration.

My profound gratitude goes to the management of DeltaAfrik Engineering Ltd. Firstly to the MD
Engr. Akinwunmi Odumakinde for availing me the opportunity to having my internship in His
prestigious company and also Mr Richard Omoarukhe (my uncle) for helping me secure my
placement in this organization.

I sincerely appreciate my understanding and supporting supervisor, Engr. Viola Chinwe Okwara
for her relentless effort to see to the success of my program despite that she was pregnant all
through my stay.

I am Sincerely Grateful to my beloved parents and my family as a whole for supporting me in

every way. I will also like to appreciate the contribution and support of wonderful people like,
Engr. Ololade Odu-onikosi, Engr. Nnukwu Amarachi, Engr. Nwafor Chinedu, Engr. Okeke
Uchenna, Engr. Omosun Yakubu, Engr. Weldone Oboke, Engr. Gobir Abdulmumuni, and the
whole Engineering Team at DeltaAfrik, who through them I learnt a lot during my stay

I sincerely acknowledge the efforts of Engr. Ibikunle Adebola, Engr. Olatunbosun Dolapo, and Mr
Abimbola Onaolapo throughout my stay at Deltaafrik. My sincere gratitude goes to all my
colleagues Babatunde Adebayo, Dafe-Akpedeye Fejiro, Olanrewaju Fatimat and so many others,
God bless you all. Special thanks to all staff of CHEMICAL ENGINEERING, UNIVERSITY OF
ILORIN for the knowledge instil in me during my 4 years and for their consistent effort towards
promoting the SIWES.

OMOARUKHE FREDRICK 3
 ABSTRACT

Students' Industrial Work Experience Scheme (SIWES), since it was introduced in 1973, has come
to be recognized as the major avenue of bridging the gap between the theory acquired by students
of tertiary institutions and the industrial practice of the various professions and disciplines essential
to the technological and economic development of a Nation.

The upstream sector of the oil and gas industry, commonly known as the exploration and
production (E&P) sector, involves providing engineering designs for oil and gas production
facilities.

DeltaAfrik Engineering Ltd, a world-class organisation functions majorly in the upstream sector
and provides engineering solutions and consultation services.

During my six months stay in DeltaAfrik was assigned to the Engineering team which comprises
of the following departments; Process, Piping, Electrical, Structural, Mechanical, Pipeline and
Loss Prevention. I worked with the Process engineering team.

This report is a summary of the experience I acquired which includes the overview of the process
discipline, theoretical overview of the oil and gas sector, and the oil and gas processing facilities
(both onshore and offshore), the cross-function experience I had from other discipline in the oil
and gas industry. It also includes the major trainings I attended in AutoCAD, Aspentech HYSYS,
Line sizing and HAZOP/HAZID sessions I attended.

OMOARUKHE FREDRICK 4
TABLE OF CONTENT

ACKNOWLEDGEMENT .............................................................................................................. 3
ABSTRACT .................................................................................................................................... 4
LIST OF TABLES .......................................................................................................................... 6
LIST OF FIGURES ........................................................................................................................ 6
CHAPTER ONE ............................................................................................................................. 7
1.1 STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)............... 7
1.1.1 Objectives of SIWES............................................................................................... 7
1.1.2 Importance of SIWES............................................................................................. 8
1.2 SCOPE............................................................................................................................. 8
1.3 AIMS AND OBJECTIVES ........................................................................................... 8
1.4 INTRODUCTION TO DELTAAFRIK ...................................................................... 8
1.4.1 Overview .................................................................................................................. 8
1.4.2 Corporate Organisation Structure of the Company.......................................... 11
1.4.3 Departments in DeltaAfrik Engineering ............................................................. 12
CHAPTER TWO .......................................................................................................................... 16
2.1 PROCESS DISCIPLINE ............................................................................................. 16
2.1.1 Process.................................................................................................................... 16
2.1.2 Process Deliverables.............................................................................................. 16
2.2 THEORECTICAL FRAME WORK ......................................................................... 20
2.2.1 Introduction to Oil and Gas Industry ................................................................. 20
2.2.2 Overview of Oil and Gas Processing ................................................................... 22
2.3.3 Pipe Design ............................................................................................................ 35
2.3.4 Pump Design .......................................................................................................... 37
CHAPTER THREE ...................................................................................................................... 39
3.1 AUTODESK AUTOCAD TRAINING ....................................................................... 39
3.2 ASPENTECH HYSYS TRAINING ............................................................................ 41
3.3 WORLEY PARSONS LINE SIZING SOFTWARE TRAINING ........................... 43
CHAPTER FOUR ......................................................................................................................... 45
4.1 EXPERIENCE GAINED ............................................................................................. 45

OMOARUKHE FREDRICK 5
 4.2 RELATION TO COURSE OF STUDY ..................................................................... 45
CHAPTER FIVE .......................................................................................................................... 47
5.1 CHALLENGES ............................................................................................................ 47
5.2 RECOMMENDATIONS ............................................................................................. 47
5.3 CONCLUSION ............................................................................................................. 47
CHAPTER SIX ............................................................................................................................. 49
6.1 REFERENCES ............................................................................................................. 49

LIST OF TABLES
Table 1 RELATION TO PREVIOUS COURSES .................................................................. 45
Table 2 RELATION TO FUTURE COURSES ...................................................................... 46

LIST OF FIGURES
Figure 1: Organisation Partnership Chart ....................................................................................... 9
Figure 2: Corporate Organisation Structure .................................................................................. 11
Figure 3: Engineering Department................................................................................................ 14
Figure 4 Engineering Department ................................................................................................ 15
Figure 5: Typical Oil Facility ....................................................................................................... 26
Figure 6: Horizontal Separator...................................................................................................... 26
Figure 7: Vertical Separator .......................................................................................................... 26
Figure 8: Three-stage separation ................................................................................................... 28
Figure 9: Typical Gas Facility ...................................................................................................... 30
Figure 10: 3-phase separator ......................................................................................................... 33
Figure 11: Process Flow Diagram (AutoCAD) ............................................................................ 39
Figure 12: Piping & Instrumentation Diagram (AutoCAD) ......................................................... 40
Figure 13: Process Flow Diagram with Backsheet (AutoCAD) ................................................... 40
Figure 14: Oil Stabilization; Multi-Stage Flashing (HYSYS) ...................................................... 42
Figure 15: Gas Dehydration; TEG Contactor (HYSYS) .............................................................. 42
Figure 16: Heat and Material Balance Sheet ................................................................................ 43
Figure 17: Line Sizing Spreasheet ................................................................................................ 44

OMOARUKHE FREDRICK 6
 CHAPTER ONE
1.1 STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
In response to the criticisms by employers that graduates of Nigeria’s tertiary institutions lacked
appropriate technical skills preparatory to employment in industry, the ITF initiated the Student’s
Industrial Work-Experience Scheme (SIWES) in 1973 with the principal objective of diminishing
the gap that may exist between the theoretical knowledge of graduates of tertiary institution in
practice of engineering, technology, allied discipline and other professional educational services
and the skills set that employers require for handling their equipment and machines. SIWES
training program forms part of the approved Minimum Academic Standard in the various degree
programs for all the Nigerian Universities. SIWES is coordinated by the National Board for
Technical Education (NBTE) for students in the university, polytechnic and colleges of education.
This program is coordinated and sponsored by the Industrial Training Fund (ITF) for universities
and polytechnics for a period of six months.

1.1.1 Objectives of SIWES

The major objectives of the Industrial Training accrued to students who participate conscientiously
in the program are the skills and competencies acquired. Also, it is key in providing a broader
knowledge about their chosen disciplines, thereby, illuminating their career path.

The goals for establishing the SIWES as listed by the Industrial Training Fund (ITF) include:

❖ To prepare the students for the work situation they are likely to come across after
graduation.

❖ To create opportunity for students in Nigeria institutes of higher learning (universities and
polytechnics) to gain industrial skills and work experience for their course of study.

❖ To provide the student with an opportunity to apply their theoretical knowledge into real
life situations, thereby creating a “hand shake” between theoretical university work and
practical experience.

❖ To make the transition from the university to the outside world of work much easier, and
thus enhance the students’ contacts for later job placement.

OMOARUKHE FREDRICK 7
In fact, the benefit of the programme to the employer from the objectives include among others,
that through properly structured training program train the student in a manner that could suit his
requirements so that the student return, on completion of his studies, to the company, less time and
money would be expended on his on-job training. The reverse should be the case when he is not
opportune to participate in the training program.

1.1.2 Importance of SIWES

❖ The scheme helps students to relate and develop the theoretical knowledge gained in school
to industrial experience.
❖ The scheme allows students to interact with workers and with the community and the future
task ahead.
❖ It enables students to understand the safety precautions involved while working in industry,
to protect and prevent themselves and environment from health hazard.
❖ It discloses to students the mode of operation of both private establishment and
government.
❖ It also improves the nation’s economy in paying experts heavily to operate machines, since
fresh graduate, already have the required experience.

1.2 SCOPE
DeltaAfrik Engineering Limited is involved in different phases of engineering in the oil and gas industries.
The scope of these report will be based in the discipline I was involved with which is the Process discipline.

1.3 AIMS AND OBJECTIVES

❖ To highlight the personal experience gained during my stay at DeltaAfrik.
❖ To enumerate the process, procedures and the components involved in Process design.
❖ To discuss the importance of Student Industrial Work Experience.

1.4 INTRODUCTION TO DELTAAFRIK

1.4.1 Overview
The Oil and Gas Sector is a fast-growing industry in the World’s Global Market which provides
more than 60% of Nigeria revenue for the past decades till date. There are different companies in
the Oil and Gas Sector, which DeltaAfrik Engineering Limited is a World-Class Organization

OMOARUKHE FREDRICK 8
which provides Engineering Design of Oil and Gas Production Facility (NBR Service) for E&P
Companies such as Mobil, Chevron, Shell, etc. under the Nigeria Law and Authority of the NNPC.

DELTAAFRIK Engineering Limited was incorporated in August 2003 under the law of Federal
Republic of Nigeria jointly owned by DeltaTek Engineering Limited which is 100% Nigerian
Engineering Company and was incorporated in 1993, It is 100% owned by Nigerians (it was set
up to provide Engineering Solutions and Consulting services in the Nigerian Oil & Gas Industry),
and Worley Parsons, an Australian Company which acquired Parsons E&C in October, 2004 Head
Office in Sydney, Australia, has offices in more than 38 countries worldwide, Over 32,000
employees worldwide, Expertise in Oil & Gas, Refining, Power, Chemicals & Petrochemicals
since 1944.

DeltaTek 51% WorleyParsons 49%

(100% Indigenous Company)

DeltaAfrik
Figure 1: Organisation Partnership Chart

VISION STATEMENT

“To be the project delivery company of choice in Africa”

MISSION STATEMENT

“To provide world class project delivery services focus on creative solution with an absolute
commitment to safety, quality and integrity”

OMOARUKHE FREDRICK 9
SAFETY POLICY STATEMENT

“Safety is not negotiable. Accident and injuries are never accepted with industrial leadership in
health, safety and environment performance”.

CORE VALUES

“DeltaAfrik has seven differentiators core values acronym as AFRIC2A”

A Addiction to Safety
F Focus on Quality
R Respect
I Integrity
C2 Creativity & Commitment to Excellence

A Accountability

DeltaAfrik provides Services in the following areas:

i. Engineering Studies.

ii. Front-End Engineering Design (FEED).

iii. Detailed Engineering Design (DED).

iv. Procurement Services.

v. Project and Construction.

OMOARUKHE FREDRICK 10
 The services listed above are offered for:

❖ HYDROCARBONS (OIL &GAS).

- Offshore Production Facilities.

- Onshore Production Facilities.

- Deep Water Production.

❖ POWER.

- Gas Turbine Power Plant.

- Renewable Energy.

- Transmission Network.

❖ INFRASTRUCTURE &ENVIRONMENT.

- Coastal &Marine.

- Water & wastewater.

- Environment.

- Master Planning.

1.4.2 Corporate Organisation Structure of the Company

DeltaAfrik Engineering Limited is structured in a pattern that enables every department in the
company to run smoothly and make every employee to perform at optimum efficiency.

Managing
Director

Executive
Managing
Director

OMOARUKHE FREDRICK 11
Manager, Manager, Legal/Administrator
Engineering Manager, Business
Finance/Account
Manager (QA/QC) Development
s
1.4.3 Departments in DeltaAfrik Engineering
There are various departments in DeltaAfrik, and all work together to make it the engineering
company of choice. They include;

• Engineering.
• Finance and Accounts.
• Human Resource.
• Information and Communications Technology (ICT).
• Procurement and Contracts.
• Quality Assurance and Control.
• Administration.
• Business Development.
• Management of Projects (MOP).
• Health, Safety and Environmental Security (HSES).

1.4.3.1 Engineering Department.

On resumption at DeltaAfrik, I was assigned to the Engineering Department and attached to work
closely with the process engineers. A training plan was drawn by my supervisor which entailed
me learning various parts of the process discipline, and also assigned me to a process engineer
whom I work directly with during the six months.
The Engineering department is one of the major departments of the company. It is a very technical
department, vast in different diversities of staff from various nationalities and ethnic groups. The
major duty of the department is to properly and efficiently execute projects and providing other
consultancy services. This department works closely with the management of projects (MOP)
departments in achieving its goals.
The sub-divisions of the Engineering Department are known as disciplines which all work hand in
hand to ensure optimal project delivery.

Process
The process team is composed of the lead process engineer, senior process engineers, senior
process designers and other process engineers/designers, who are assigned to various projects.
He/she works closely with engineers from other discipline in achieving their objectives. They are

OMOARUKHE FREDRICK 12
the ones who design begins with, they analyse the product that’s being drilled, give the sizing of
the equipment that will produce the crude. They produce the PFD (process flow diagram) and the
P&ID (piping and instrumentation diagram) which gives a detailed view of the PFD. They also
design the valves and the location of their placement in the facility.

Mechanical/Piping
They aid in the design of many of the equipment used, equipment such as; the design of cranes,
process equipment, pumps and compressors, data sheets and the equipment list. They also oversee
the design of the plot plan, the routing of the pipes within the facility, the designing of the layout
of the facility.

Instrumentation and Controls

They help in the design of the controls of the facility, enabling control over some equipment within
the facility from a location. Equipment such as; pressure valves and sensors, temperature valves
and sensors, flow rate valves and sensors level equipment as well are all controlled by this
discipline.

Pipeline
They are in charge in the design of pipes used in the transportation of the product from one platform
to another if they are not connected by a bridge, that is the platform is in a remote or satellite
location and to the facility of the client downstream.

Safety & Risk

They are in charge in making sure safety is applied by all disciplines in their various designs. They
also design fire system, deluge systems to aid in combating fire outbreaks. They also make sure
the designed escape routes don’t have obstructions in its path.

Electrical
They design the power and lightening of the facility, the electrical layout of the wirings around the
facility, designing of the electrical equipment; cables, generators and turbines of the facility.

OMOARUKHE FREDRICK 13
Civil/Structural
They are involved in all works having to do with concrete. They design drainage, roads, ramps,
convents and the foundation layout. They are involved in all constructions involving steel; they
design mostly for offshore platforms. The jacket, the deck and all steel work around the facility is
designed by them.

An interface exists among all these disciplines when designing oil/gas production facilities as a
slight change in any process parameter affects the entire facility.

It is important to know that the managements of project (MOP) department works alongside with
the engineering department to ensure the documents and drawings are sent to the clients at the
right time and in the right format. In other word, the MOP department manages and controls all
projects.

Figure 4 Bay Atlantic Tower

OMOARUKHE FREDRICK 14
 Managing
Director

Engineering Manager

Design Office Manager Procurement

Document Control
Manager

IT Network Administrator

Lead Lead Lead Lead Lead Electrical Lead

Process Mech/Piping Pipeline Instrumentation Engineer Civil/Structural
Engineer Engineer Engineer Engineer Engineer

Snr Process Snr Snr Pipeline Snr Snr Electrical Snr Civil/Structural
Engineer Mechanical/Pipin Engineer Instrumentation Engineer Engineer
g Engineer Engineer

Process Mech//Piping Pipeline Instrumentation Electrical Civil/Structural

Engineer Engineer Engineer Engineer Engineer Engineer

Process Mech/Piping Pipeline Instrumentation Electrical Civil/Structural

CADD CADD Designer CADD CADD Designer CADD CADD Designer
Desingner Desinger Desingner

SIWES SIWES SIWES SIWES SIWES SIWES

Figure 5 Engineering Department

OMOARUKHE FREDRICK 15
 CHAPTER TWO
2.1 PROCESS DISCIPLINE
2.1.1 Process
Process is a discipline in design engineering that involves designing and sizing equipment, understanding
the reactions taking place, installing control systems, and starting, running and upgrading the processes.
Environmental protection, health and safety aspects are also significant concerns.

The typical work activities include:

❖ Assessing processes for their relevance and assessing the adequacy of engineering equipment;
❖ Designing, installing and commissioning new production units, monitoring, modifications and
troubleshooting existing processes;
❖ Reviewing existing data to see if more research and information need to be collated;
❖ Applying the principles of mass, momentum and heat transfer to process and equipment design,
including conceptual, scheme and detail design;
❖ Preparing reports, flow diagrams and charts;
❖ Assessing the availability of raw materials and the safety and environmental impact of the plant;
❖ Managing the cost and time constraints of projects;
❖ Selecting, managing and working with sub-contractors.
❖ Assuming responsibility for risk assessment, including hazard and operability (HAZOP) studies,
HAZID studies for the health and safety of both company staff and the wider community;
❖ Ensuring the process works at the optimum level, to the right rate and quality of output, in order to
meet supply needs;
❖ Ensuring that all aspects of an operation or process meet specified regulations;
❖ Working closely with the specialists, including: engineers responsible for plant maintenance;
commercial colleagues on product specifications and production schedules; and the operating crew.

2.1.2 Process Deliverables

Process engineering is the key part of any project and it subjective is to define initial elements and develop
design in several consecutive steps. Some major process deliverables include:

❖ Process Design Procedures

❖ Basis of Design (BOD)
❖ Process Calculation
❖ Operation Philosophy

OMOARUKHE FREDRICK 16
 ❖ Process Flow Diagram (PFD)
❖ Piping and Instrumentation Diagram (P&ID)
❖ Heat and Material Balance
❖ Utility Flow Diagram (UFD)
❖ Process Safety Flow Diagram (PSFD)
❖ Safety Analysis Function Evaluation (SAFE) Chart
❖ Line Schedule
❖ Tie-in Schedule
❖ Equipment List
❖ Data Sheet
❖ Simulation Report
❖ Calculation Report.

The client requirements are found in the contract engineering Basis, which describes “what” and “how”
to deliver from a technical perspective. It includes both project specific functional requirements, which
include the scope of work and the design basis, and general requirements such as Client’s design standards
and specifications.

How to process the inlet fluid(s) to produce the required product(s) i.e., the Process, will be defined by
performing Process Simulations. These simulations use thermodynamic models to simulate fluid
behaviours under the different process operations: phase, separation, compression, heat exchange,
expansion, etc. The software also calculates the duty of the equipment. Such calculation is difficult to make
manually as Petroleum fluids contain a large variety of components. Running process simulations will allow
to try several scenarios and optimize the process, i.e., reduce the number of equipment, energy consumption,
etc.

Once the optimum scheme is found, Process displays it on the Process Flow Diagrams (PFDs) that shows
the process equipment, e.g., separator, heat exchanger, compressor, etc., and their sequence.

The Process Equipment List is the register of all Process Equipment. It is derived from the PFDs.

Process simulations are run for all operating cases, such as initial year of operation, plateau level, operating
case at the field end of life when water to oil ratio (water cut) has increased significantly, etc. This
determines the required capacity of each equipment. Minimum and maximum duties are identified covering
the full range of operating cases. The range of operating conditions for each line (pressure, temperature,

OMOARUKHE FREDRICK 17
flow) is also identified, which will allow adequate line specification and sizing. The results are tabulated in
the heat and material balance, which shows the flow, composition and condition of each streams.

Process then performs the sizing of equipment as per the required process duty, e.g., sizing the gas
compressor according to required gas flow and gas gravity, size of cooling water pump as per process fluid
cooling requirements, and Site conditions, e.g., temperature of available cooling medium (air/sea water).
The process duty of each equipment is specified in a Process data sheet.

The PFDs also show how the process will be controlled by indicating the required controls (of
pressure/temperature/flow) throughout the process scheme. This is further described by Process in the
Process Description and Operating Philosophy.

As the process diagram is further detailed, PFDs are translated into Piping and Instrumentation Diagram
(P&IDs). P&IDs show in detail the equipment, piping, valves (manual/motorized), instrumentation,
process control and emergency shutdown devices. It does not only include all lines, instrument, values
required during normal operation, but also the ones required for maintenance, plant start-up and all
operating cases. They will include, for instance, equipment isolation valves, depressurization and drainage
lines. The Legend and Symbols P&ID shows the meaning of the graphical elements and symbols used on
the P&IDs. This is generally used to provide a means of communicating instrumentation, automation and
control requirements that all parties can readily understand.

Process controls, which are directly shown on P&IDs by means of dotted lines between controlled process
parameter (pressure, flow, temperature) and control valve and process automations (ON/OFF controls) are
described in a specific diagram called Process Safety Flow Diagram.

Process also numbers each line and maintains the corresponding register, called Process Line List. It shows
the process information of each line namely, fluid type, fluid phase, operating and design temperature and
pressure, etc.

Process calculates the diameter of lines, based on hydraulic requirements (maximum flow velocity pressure
drop allowed or erosion criteria), shows the details of the calculations in Calculation Report and indicates
resulting line diameters on the P&IDs.

Finally, Process issues the operating manual, containing a detailed description of the facilities, instructions
for start-up, operation and maintenance.

OMOARUKHE FREDRICK 18
Process Design Engineering is the design of processes for desired physical and/or chemical transformation
of material. It can be the design of new facilities or it can be the modification or expansion of existing
facilities. The design starts at a conceptual level and ultimately ends in the form of fabrication and
construction plans.

CONCEPTUAL STUDY
Conceptual study is the first step of any project. At this stage one or more means of accomplishing the
objectives will be investigated. An economic and technical assessment and comparison of the various
methods or scheme is made. Block diagram and analysis of alternative costs are the tools used in the
conceptual study.

This project phase also involves;

❖ Developing project requirements, proposing & optimizing solutions, estimating costs, and
evaluating the economics of a project.

❖ Collecting data necessary to perform work (equipment and instrument data, piping layout
configuration, miscellaneous data).

❖ Carrying out process simulations, engineering calculations, providing information to supporting

disciplines, support estimating activities.

❖ Conceptual engineering work such as developing preliminary material balances and process flow
diagrams.

❖ Issue Report (summarized study results, clearly present pertinent information and make
recommendations as appropriate.

Process deliverables during the conceptual studies include; Block flow diagrams, Process design basis and
criteria, Process description, Process flow diagrams, Reports, and Back-up Calculations.

FRONT-END ENGINNERING DESIGN (FEED)

Once the need for an engineering assistance is determined, design engineering must begin so as to translate
the process flow diagram (PFD) into specific objectives and determine the activities that will be required
to attain these objectives.

This activity entails;

❖ Completing first-pass process, control systems, and mechanical engineering design activities.

OMOARUKHE FREDRICK 19
 ❖ Developing cost estimates for the project.

❖ Supporting environmental studies and permitting.

❖ Develop simulation model (optimize the unit, determine unit design cases)

❖ Generate heat & material balance

❖ Develop process flow diagrams (finalize unit configuration, determine alternate processing
schemes). Develop P &IDs (in-house reviews, joint reviews, HAZOP reviews)

❖ Identify hazardous materials, identify safety systems.

❖ Develop equipment specifications (set equipment design conditions, perform hydraulic calculations
& line sizing), size major equipment.

Process design deliverables during FEED include; Simulation output, Heat & material balance, PFDs and
P&IDs, Equipment list, Equipment and Instrument Data Sheets, Control narratives, Utility summary, Relief
Load Summary, Piping Line List, Deviation Reports, Back-up calculations & correspondence

2.2 THEORECTICAL FRAME WORK

2.2.1 Introduction to Oil and Gas Industry

The oil and gas industry includes the global processes of exploration, extraction, refining,
transporting (often by oil tankers and pipelines), and marketing petroleum products. The largest
volume products of the industry are fuel oil and gasoline. Oil is also the raw material for many
chemical products including pharmaceuticals, solvents, fertilizers, pesticides, and plastics. The
industry is usually divided into three major components: upstream, midstream and downstream.
Midstream operations are usually included in the downstream category.

Petroleum is vital to many industries, and is of importance to the maintenance of industrial

civilization in its current configuration, and thus is a critical concern for many nations. Oil accounts
for a large percentage of the world’s energy consumption, ranging from a low of 32% for Europe
and Asia, to a high of 53% for the Middle East.

OMOARUKHE FREDRICK 20
CLASSIFICATION OF THE OIL AND GAS INDUSTRY BY SECTORS
This sector by structure can broadly be divided into;

The Upstream Sector

The upstream sector includes searching for potential underground or underwater crude oil and
natural gas fields, drilling exploratory wells, and subsequently drilling operating the wells that
recovers and bring the crude oil and/or natural gas to the surface. This sector is also widely known
as the exploration and production (E&P) sector. Examples of companies involved in this sector,
include: SPDC, CNL and TOTAL.

The Downstream Sector

The downstream sector commonly refers to the refining of petroleum crude oil and the processing
and purifying of raw natural gas, as well as the marketing and distribution of products derived
from the crude oil and natural gas. Such product can include LPG, gasoline, jet fuel, diesel fuel.
The downstream segment includes oil refineries, petrochemical plants, petroleum distribution
outlets, retail outlets and natural gas distribution companies.

OMOARUKHE FREDRICK 21
2.2.2 Overview of Oil and Gas Processing
AG/NAG wells produce a mixture of hydrocarbon gas, condensate, or oil; water with dissolved
minerals, usually including lots of salt; other gases, including nitrogen, carbon dioxide (CO2), and
possibly hydrogen sulphide (H2S); and solids, including sand from the reservoir.

For the hydrocarbons (gas or liquid) to be sold, they must be separated from the water and solids,
measured, and transported by pipeline, truck, rail, or ocean tanker to the user. Gas is usually
restricted to pipeline transportation but can also be shipped in pressure vessels on ships, trucks, or
railroad cars as compressed natural gas or converted to a liquid and sent as a liquefied natural gas
(LNG). This section discusses the field processing required before oil and gas can be sold.

The goal is to produce oil that meets the client’s and regulatory body’s specifications that define
the maximum allowable water, salt, or other impurities. Similarly, the gas must be processed to
meet client’s water vapour and hydrocarbon dew point specifications to limit condensation during
transportation. The produced water must meet regulatory requirements for disposal in the ocean if
the wells are offshore, reservoir requirements for injection into an underground reservoir to avoid
plugging the reservoir, and technical requirements for other uses, such as feed to steam boilers in
thermal-flood operations, or in special cases, for irrigation.

The equipment between the wells and the pipeline, or other transportation system, is called an
oilfield facility. An oilfield facility is different from a refinery or chemical plant in several ways.
The process is simpler in a facility, consisting of phase separation, temperature changes, and
pressure changes, but no chemical reactions to make new molecules. In a refinery, the feed-stream
flow rate and composition are defined before the equipment is designed.

OMOARUKHE FREDRICK 22
Definition of Terms
The following definitions are used in this section.

Crude oil is a liquid hydrocarbon produced from a reservoir.

Condensate is liquid hydrocarbon that condenses from the gas as pressure and temperatures
decrease when the gas is produced from the reservoir up the tubing and out the wellhead choke.
Condensate is usually lighter in colour and lower in molecular weight and viscosity than crude oil;
however, a light crude oil could have properties like a condensate.

Hydrocarbons are composed of many different “components” or molecules of carbon and

hydrogen atoms. Starting with the lightest molecular weight, they are methane (CH4), ethane
(C2H6), propane (C3H8), and so on. As the ratio of carbon to hydrogen atoms increases, the
molecules become “heavier” and have a greater tendency to exist as a liquid rather than a gas.

OMOARUKHE FREDRICK 23
An oilfield facility is a collection of equipment that is used to separate the fluids that come out of
an oil or gas well into separate streams that can then be sold and sent to a gas plant or refinery for
further processing.

A process simulation is a calculation, usually done with a computer program that predicts how
the components that make up the well fluids react to changes in pressure and temperature as they
are processed through the facility. This is not a chemical reaction, but rather a simple phase change
as liquids flash to vapour or vapours condense into liquid. As the pressure is reduced or the
temperature is increased, the lighter molecules, such as methane and ethane, tend to boil off into
the vapour phase, taking some of the midrange components with them. The remainder of the
midrange and most of the heavier molecules stabilize as liquid.

Basic sediment and water (BS&W) is the percent by volume of water and solid impurities in the
oil. Oil pipeline specifications range from 0.1 to 3%, with a typical Gulf of Mexico pipeline
requirement of 1% by volume.

The bubble point, or true vapour pressure, is the point at which gas first appears within a liquid
sample as the temperature is raised or the pressure lowered. The bubble point of a hydrocarbon
liquid is a function of pressure, temperature, and the composition of the liquid.

Reid vapour pressure is the pressure at which a hydrocarbon liquid will begin to flash to vapour
under specific conditions. It results in a pressure lower than the true vapour pressure.

The hydrocarbon dew point is the point at which hydrocarbon liquid first condenses from a gas
sample when the temperature is lowered or the pressure is increased, and it depends on the
composition of the gas. The water dew point is often specified for gas pipelines for hydrate and
corrosion control. Depending on the history of the hydrocarbon fluid, the hydrocarbon and water
dew points may not be the same.

Hydrates are crystalline, ice-like solids that form in the presence of hydrocarbon gas and liquid
water. Hydrates can form at temperatures significantly higher than the freezing point of water and
can plug equipment and pipelines.

OMOARUKHE FREDRICK 24
Function of an Oil and Gas Processing Facility
Main Process
The main function of an oil facility is to separate the oil, gas, water, and solids; treat the oil to meet
sales specifications (e.g., BS&W, salt content, vapour pressure); measure and sample the oil to
determine its value; and deliver it to the transportation system (i.e., the pipeline, truck, ship, or
railroad car).

The gas must be treated for sales or disposal. In the past, disposal sometimes meant flaring or
venting, but now gas that can’t be transported is usually compressed for reinjection into the
reservoir. Gas treating may involve only separation from the liquids, or it may include additional
processes such as compression, dehydration, removing H2S and CO2; or gas processing to
condense heavier components that can be transported as a liquid.

In addition to processing the oil and gas for sale, the produced water and solids must be treated for
disposal. For produced water, treating usually includes removal of dispersed and dissolved
hydrocarbons and, in addition to separation or oil skimming, may include filtration, deionization,
or pumping.

Auxiliary Systems
In addition to the process systems, auxiliary process heating and cooling may be required. Process
heat is usually needed for oil treating and superheating fuel gas for use in gas turbine generators
or compressors. Process cooling is usually required for gas compression. While, if necessary,
facilities can be run without electric power, power generation and electrical systems will usually
be included for a facility that is large or complex or for living quarters that are provided for
personnel.

All facilities require safety systems, including safety instrumentation and shutdown system; fire
and gas detection; fire-fighting equipment; a means of evacuation, such as life rafts and escape
capsules for offshore; and other equipment, depending on the location and complexity of the
facility and whether it is manned.

Fig. 5 is a block diagram of a simple oil facility.

OMOARUKHE FREDRICK 25
Figure 6: Typical Oil Facility

Separation
The first step in the process is separating the gas from the liquid and the water from the oil. This
is usually done in a separator—a pressure vessel into which the well stream flows to allow the gas,
oil, and water to separate because of gravity. Separators may contain inlet diverters, outlet vortex
breakers, buckets, weirs, and mist extractors to aid separating the streams.

Figure 7 Horizontal Separator

Figure 8 Vertical Separator

A separator may be two-phase, separating gas from liquids, or three-phase, separating gas, oil, and
water, which are removed through three outlets. The first separator in a facility that receives fluid

OMOARUKHE FREDRICK 26
from the wells is called a production, or high-pressure (HP), separator. If the production is at high
pressure, (e.g., 500 to 1,200 psig) and if the oil from the separator is put directly into a pipeline,
gas will flash as the pressure decreases owing to friction losses in the pipeline. Gas takes up a
much larger volume than its equivalent mass of oil, so a pipeline sized for liquid flow will be
undersized if some of the liquid flashes into gas, resulting in excessive velocities and pressure
drop. For this reason, oil pipeline owners generally specify a maximum vapour pressure allowed
to prevent the lighter components in the oil from flashing into gas. The process of reducing the
vapour pressure in the oil to meet oil-pipeline specifications is called “stabilization.”

For the simplest form of stabilization, the oil is put into an atmospheric tank for storage. This
allows the gas to flash from the liquid in the tank when the pressure is reduced to atmospheric.
This process would get the true vapour pressure of the oil down to atmospheric, or even lower if
some heating were added in addition to the pressure reduction, and could be used to make the oil
meet pipeline specifications for vapour pressure. The gas that flashes in the tank must then be
compressed back to the original pressure of the separator and combined with the separator gas. If
the oil is sent to an intermediate pressure (IP) separator instead of going directly into an
atmospheric tank, the gas that flashes in the IP separator will be at a higher pressure, requiring less
compression horsepower. In addition, the total amount of oil stabilized in the atmospheric tank is
greater with an intermediate separation stage than with a single flash to atmospheric pressure. This
is because of the gas/liquid equilibrium for the higher-pressure flash and the altered composition
of the oil that is flashing in the tank.

While there still would be, gas flashed as the liquid flowed from the IP separator to the tank, the
quantity would be much smaller than in the first case in which liquid goes directly from the HP
separator to the tank. Thus, adding a second stage of separation has two benefits: first, the
horsepower required to compress the gas is lower because some of the gas flashes at higher
pressure, and second, more stabilized oil will be produced. If we add a third, low-pressure (LP)
stage of separation, the total liquid in the tank increases even further, with additional gas flashing
at a higher pressure, reducing compressor horsepower.

Fig. 8 shows a typical three stage separation with flash-gas compression. Adding additional stages
of separation and compression would increase liquids and reduce compression horsepower further;

OMOARUKHE FREDRICK 27
however, at this point, the capital cost of adding additional separation stages is generally not worth
the small increase in hydrocarbon value.

Figure 9: Three-stage separation

A typical separation train might have a well producing into an HP separator at 1,100 psig, with the
oil to an IP separator at 450 psig, an LP separator at 150 psig, and possibly an oil treater at 50 psig
(see next section) before storage in an atmospheric tank. The separator pressures are chosen so that
the flash gas from each stage of separation feeds into a stage of compression with reasonable
compression ratios for each stage of the compressor.

Oil Treating
The crude oil sold to refineries has had free water removed, meeting the specification for water
content in oil, which is 0.5%. Before the oil can be processed in a refinery more water must be
removed. The water, which remains in the oil, does so as water droplets suspended in the oil, this
water is invariably slat water. Oil treating is to reduce the water and salt content in crude oil to the
following specification;

❖ Water in crude oil, Basic Sediment and Water BS&W <0.5%

OMOARUKHE FREDRICK 28
 ❖ Salt in crude oil 72 g/m3

High water content can make corrosion problems worse in pipelines and other transportation
systems and can cause problems with downstream processing. High salt content, which is caused
by the salinity of the produced water left in the oil, may cause a refining problem when the water
is boiled off in the refinery distillation unit.

To get the last of the water out of the oil, the oil is processed through an oil treater or a treating
system. A treater is like a separator, but with special features to help separate the water from the
oil. Treaters or treating systems usually provide heat to reduce oil viscosity and large settling
sections to allow the water time to settle from the oil, and may provide an electrostatic grid to
promote coalescing of the water droplets. Conventional treaters usually have a front section with
a heater in which the emulsion is heated and initial separation of the “free water” takes place. The
oil then flows to a second section of the vessel, where additional coalescence and settling of the
water droplets takes place. Gas is flashed (i.e., liberated) from the emulsion as the pressure is
lowered and the temperature is raised from the upstream separator. For a conventional treater with
a heater, free-water knockout section, and settling section, the water content in the oil can be
reduced to less than 1%. An electrostatic treater, which is a conventional treater with an
electrostatic grid in the settling section, can reduce the water content to 0.3 to 0.5% by volume.
The oil from the treater is usually sent into a dry oil tank, from which it is pumped through a sales
meter for custody transfer, and then into a pipeline for transportation.

Separated water from the well fluids is directed to the produced water treatment unit to render the
water suitable for disposal to onshore or offshore depending where the reservoir is located. Oil
removal is the first treatment for produced water. Oily-water emulsions are difficult to clean up
due to the small size of the particles, as well as the presence of emulsifying agents. Hydrocyclone
is common equipment for produced water de-oiling purpose. Alternatively, the produced water
could be re-injected into water injection wells. Before re-injection, produced water is usually
filtered and treated with biocides. Booster pumps and injection pumps are normally installed for
water injection.

Gas Facility
Fig. 9 is a block diagram of a simple gas facility. Each of the main blocks is described here.

OMOARUKHE FREDRICK 29
Figure 10: Typical Gas Facility

Heating
Gas wells are often high pressure with a shut-in tubing pressure of 5,000 to 15,000 psig and a
flowing tubing pressure more than 3,000 psig. This pressure must be reduced to the appropriate
pipeline pressure at the point at which the gas flows through a wellhead choke. When gas pressure
is reduced, the gas cools, liquids can condense, and hydrates can form. These hydrates can plug
the choke and flowline, so high-pressure gas wells usually require a line heater that contains the
flowline and choke inside a hot water bath to keep the well from freezing.

Separation
The separator provides a place for any liquid to settle out from the gas. The separator pressure is
set higher than the pipeline pressure so that the gas can go through the required cooling, treating,
dehydration, and gas processing—each with some pressure drop—and arrive at the required
pipeline pressure.

Cooling
If the flowing tubing temperature is even higher, the hot gas leaving the HP separator could cause
process and corrosion problems with the downstream treating system. In addition, the hot gas will

OMOARUKHE FREDRICK 30
carry more water vapor, which makes the dehydration system larger and much more expensive
than if the gas were cooled first. Thus, it is sometimes necessary to install a gas cooler downstream
of the first-stage separator. The cooler may be an aerial cooler or a shell-and-tube exchanger that
uses either direct seawater or a contained cooling-water loop, which is cooled by seawater or some
other water source.

Gas Dehydration
To avoid water condensing in the gas pipeline with resulting corrosion and hydrate-formation
problems, pipeline specifications usually limit the amount of water vapour in the gas. A standard
pipeline specification is 7 lb. of water per million standard cubic feet of gas (lb. /MMscf).

Water is often removed from gas with a glycol dehydration system. Other methods include solid-
desiccant adsorption, refrigeration, and membrane permeation. Glycol dehydration systems
commonly use triethylene glycol to absorb the water vapour from the gas. This is done in a contact
tower in which the lean, or dry, glycol flows by gravity from the top of the tower through trays or
structured packing. The gas flows counter current up through the tower so that the driest gas
contacts the driest glycol. The dry gas exiting the tower is used to precool the lean glycol before it
enters the tower. The gas then continues to sales or to further processing to remove natural-gas
liquids (NGLs). The rich, or wet, glycol exiting the bottom of the tower is regenerated in a
continuous process.

First, the rich glycol goes to a separator to remove any condensed hydrocarbons; then it is
preheated and filtered before being sent to a “reboiler” or “regenerator.” The rich glycol is heated
in the regenerator up to 390 to 400°F, and the water is boiled off. This vapour is either discharged
directly to the atmosphere or is cooled and condensed to separate the small amount of hydrocarbon
vapours from the water. The resulting hot, lean glycol is then cooled through a cross exchanger
with the cool, rich glycol coming from the contact tower. The cross exchanger makes the process
more efficient and preheats the glycol going to the reboiler, which reduces the overall energy
requirements. The reboiler may be heated by a gas-fired heater, electric heating elements, or a
heat-medium system.

OMOARUKHE FREDRICK 31
Gas Treating
Natural gas may have several impurities, such as H2S and CO2, which are referred to as “acid
gases.” Natural gas containing H2S is called a sour gas; if the gas contains no H2S, or if the H2S
has been removed, it is “sweet gas.” The process of removing the H2S, and possibly CO2, is
referred to as “sweetening.” H2S gas is highly toxic. CO2 forms a strong acid that is highly
corrosive in the presence of water.

A common way to remove H2S and CO2 from natural gas is with an amine system, which uses a
contact tower with trays or structured packing to pass the sour gas through the amine liquid,
absorbing the H2S and some of the CO2. The amine is then regenerated in a stripping tower in
which the H2S and CO2 are removed.

Gas Processing
The dry gas may be further processed to recover liquid hydrocarbons in the form of NGLs, LNGs,
or liquefied petroleum gas (LPG). NGLs are hydrocarbon liquids, such as ethane, propane, butane,
and natural gasoline that can be separated from a natural-gas stream after the heavier hydrocarbon
components have already been removed by separation at ambient temperatures. LPG is a mixture
of hydrocarbons—principally butane and propane—that can be transported as a liquid under
pressure, or at very low temperatures. And converted to gas on release of the pressure. LNG is a
liquid composed of mostly methane that is liquefied to make it easy to transport if a pipeline is not
feasible.

Compression
The lighter components removed in the gas phase during the stabilization process will be at a lower
pressure than the main gas stream. These components must be compressed to the HP-separator
pressure so they can be processed with the rest of the gas.

Process Control
A separator operates through a continuous, rather than a batch, process. This means that the inlet
stream constantly flows into the separator and that the gas and liquid must be removed at the same
rate. For liquids, this is done by means of a level controller and level valve. The traditional level
controller consists of a float on a spring. As the liquid level in the separator rises, the float rises
until it closes a switch, which then opens the level valve to let out some liquid. When the level
falls back down to the normal operating level, the switch opens again and drives the level valve

OMOARUKHE FREDRICK 32
closed. A two-phase separator uses a single liquid-level controller and level valve; a three-phase
separator will have both an oil outlet with an oil-level controller and level valve and a water outlet
with a water-level controller and level valve.

Figure 11 3-phase separator with controls

Because the liquid is incompressible and the liquid level in the separator remains constant, the gas
is contained in an approximately constant volume. As more gas enters the separator, the pressure
rises. A pressure controller is mounted on the separator-gas space or on the outlet-gas piping. The
controller sends a signal to the pressure-control valve in the gas-outlet piping telling it to open
when the pressure is higher than the set point. Pressure-control valves are usually modulating,
which means that they gradually open wider as the pressure rises to a value higher than the set
point and close as the pressure falls to a value lower than the set point.

In short, whatever amount of liquid comes into the separator, an equal amount must exit through
the level-control valve. The level controller senses whether the liquid level is high or low and
adjusts the level valve accordingly. Whatever amount of gas that comes in the inlet of the separator,
an equal amount of gas must exit through the pressure-control valve. The pressure controller senses
pressure in the separator, opening the pressure-control valve if the pressure gets higher than the
desired set point and closing it if the pressure gets lower than desired. If the inlet stream shuts off,
the outlet valves would all close, maintaining the pressure and level in the separator.

OMOARUKHE FREDRICK 33
Design Safety
If the process-control system operates correctly, operators use all manual valves correctly, and
nothing breaks, there is no need for a safety system. However, controllers malfunction, valves leak,
and operators make mistakes. The safety system is there to prevent overpressure and possible
rupture of equipment, leaks, pollution, fire, injury to personnel, and damage to equipment. Two
levels of protection normally exist in a safety system: primary and secondary.

Primary Protection
The primary protection is usually a sensor or switch on the equipment that detects the undesirable
event. For example, equipment may have a pressure, level, or temperature switch to detect values
that are too high or too low, based on the normal operating ranges. Once the undesirable event is
detected, a safety shutdown system is required to shutdown flow into the affected equipment.

Secondary Protection
In the event the primary protection fails to operate or operates too slowly to correct a problem,
there is secondary protection consisting of a pressure safety valve (PSV) to prevent overpressure.
A PSV is designed to open, relieving overpressure in a vessel or piping through “relief header”
piping that directs the relieved fluids to a safe place for retrieval or disposal. Alternatively,
secondary protection may consist of redundant sensors or switches, such as those used for primary
protection, which may be located on downstream equipment or on the equipment in question. A
separator with a given operating pressure will have a “design” pressure or “maximum allowable
working pressure” (MAWP) sufficiently greater than the operating pressures to prevent small
fluctuations in the process from causing overpressure of the pressure vessel. As an example, in the
staged-separation process, the operating pressure of each downstream separator will be lower than
that of the separator flowing into it. This allows the system-design pressure to be reduced as well.
When a higher-design-pressure system flows into a lower-design-pressure system, there is
potential for over pressuring the downstream, lower-pressure-rated system.

For example, if the liquid-level control valve fail open, there is a possibility to drain the liquid
inventory to downstream equipment. In this scenario the high pressure gas flow has a free access
to the downstream equipment without any pressure control loop on the bottom outlet line, this will
lead to overpressure. ‘Gas blowby’ can occur upon inadvertent opening of liquid level control
valves. When level control drops down below the normal level set point, low level alarms or low

OMOARUKHE FREDRICK 34
liquid level trips can be provided on the vessel to avoid gas blowby. On a low liquid level alarm,
operator must act to prevent further drop in liquid level. If the liquid level still drops, at a low low
liquid level a process shutdown should be activated by closing the automatic on-off valve on the
bottom liquid outlet line

To protect the downstream liquid handling equipment against gas blowby, appropriate relief valve
should be installed on these equipment. These relief valves should be sized to handle the gas flow
in case of gas blowby if sufficient safeguards are not present on the liquid line from separator,
against gas blowby.

In addition to primary and secondary protection for the process, an emergency support system is
used to minimize the effects of escaped hydrocarbons. This system includes combustible gas
detectors, fire detectors, smoke detectors, a containment system to collect leaking liquid
hydrocarbons, and an emergency shutdown system to provide a method for the process-control
system to initiate a platform shutdown.

2.3.3 Pipe Design

Pipe design in oil and gas production facilities involve the selection of pipe diameter and a wall thickness
capable of transporting fluid from one piece of equipment to another within the allowable pressure drop
and pressure rating constraint imposed by the process.

Fluid flow can be classified as single-phase, two-phase and multiphase depending on the number of fluid
phases involved. The single-phase flow is when the fluid is chemically uniform, physically distinct and
mechanically separable, while the two phase flow involves a combination of liquid and gas flowing through
a pipe.

Sizing Criteria-General
To determine the diameter of the pipe to be used in platform piping systems, both the flow velocity and
pressure drop should be considered. When determining line sizes, the maximum flow rate expected during
the life of the facility should be considered rather than the initial flow rate. It is usually advisable to add a
surge factor of 20 to 50 percent to the anticipated normal flow rate, unless surge expectations have been
more precisely determined by pulse pressure measurements in similar systems or by specific fluid hammer
calculation. Determination of the pressure drop in a line should include the effect of valves and fittings.
Calculated line sizes may need to be adjusted in accordance with good engineering judgement. (API 14E)

OMOARUKHE FREDRICK 35
Sizing Criteria for Liquid lines
Single- phase liquid lines should be sized based on the flow velocity majorly. For lines transporting liquids
in single phase from one pressure vessel to another to another by pressure differential, the flow velocity
should not exceed 15 feet/second at maximum flow rates, to minimize flashing ahead of the control valve.
Flow velocity should not be less than 3feet/second to minimize deposition of sands and other solids. At
these flow velocities, the overall pressure drop in the piping will usually be small. Most of the pressure
drop in liquid lines between two pressure vessels will occur in the liquid dump valve or choke.

❖ Flow velocities may be calculated using the following derived equation:

𝟎. 𝟎𝟏𝟐 𝑸𝟏
𝑽𝟏 =
𝒅𝟏 𝟐

❖ The pressure drop (psi per 100 feet of flow length) for single phase lines can be calculated
using the Fanning Equation:

𝟎. 𝟎𝟎𝟏𝟏𝟓𝒇 𝑸𝟏 𝟐 𝑺𝟏
∆𝑷 =
𝒅𝟏 𝟓

❖ The moody friction factor,𝑓, is a function of the Reynolds number and the surface roughness
of the pipe. The Reynolds number may be determined by the following equation:

𝝆 𝟏 𝒅 𝒇 𝑽𝟏
𝑹𝒆 =
𝝁𝟏

Sizing Criteria for Single Phase Gas Lines

The single-phase gas lines should be sized so that the resulting end pressure is high enough to satisfy the
requirements of the next equipment. Its velocity may be a noise problem if it exceeds 60 ft/s. higher
velocities than this are acceptable when pipe routing, valve choice are done to minimize or isolate noise.

❖ There are several ways by which the pressure drop in a gas line can be calculated, the formula
below is one and it is referred to as the general pressure drop equation

𝟏𝟐. 𝟔𝑺𝑸𝒈 𝒁𝑻𝒍 𝒇𝑳

∆𝑷 =
𝑷 𝒍 𝒅𝟓

Sizing Criteria for Two Phase Gas/Liquid Lines

The following procedure can be used to size two phase lines on platforms, floating production
systems and onshore facilities

OMOARUKHE FREDRICK 36
 ❖ The erosional velocity should be calculated and the minimum pipe size required to
avoid fluid erosion should be determined. The erosional velocity is the velocity above
which erosion can occur.
𝒄
𝑽𝒆 =
√𝝆𝒎

❖ The pressure drop should be calculated using the formula below:

𝟎. 𝟎𝟎𝟑𝟑𝟔𝒇𝑾𝟐
𝚫𝑷 =
𝒅𝟓 𝝆𝒎

2.3.4 Pump Design

A pump is an equipment that is used to increase fluid flow (velocity) by means of mechanical
action. Two major types of pumps are:

❖ Centrifugal Pumps: this pump moves the liquid by accelerating it radially outward in a
rotating impeller to a surrounding stationary housing or casing. They are preferred over
positive displacement pumps because they are usually less costly.
❖ Positive Displacement Pumps: it is a pump in which a measured quantity of liquid is
trapped in space, its pressure raised and then delivered. Positive displacement pumps
are either reciprocating or rotary types. They are usually installed for services which
high head at moderate capacity.

Several pump characteristics can be estimated using some basic equations, charts and guidelines.
These characteristics can then be used to support the design process. Key parameters for pump
specifications include:

❖ Design Flow rate: this is the flow rate from the process mass balance plus an allowance
for continuous flow recycle.
❖ Design Head: the design head is the difference between the pump discharge head and the
pump suction head.
Suction Head, 𝑯𝒔 = 𝑷𝟏 + 𝒉𝟏 − 𝑳𝑷𝟏

Discharge Head, 𝑯𝒅 = 𝑷𝟐 + 𝒉𝟐 + 𝑳𝑷𝟐 + 𝑳𝑪𝑽

Design head, 𝑯𝑻 = 𝑯𝒅 − 𝑯𝒔

OMOARUKHE FREDRICK 37
 ❖ Pump Motor Rotative Speed: in centrifugal pumps the number of stages, efficiency and
Net Positive Suction Head required (NPSHr) are all dependent on the impeller speed. The
speed for a two-pole motor is 3000rpm for 50Hz power frequency, and 1500 rpm for a
four-pole motor. For reciprocating pumps the typical speed is 180 rpm.
❖ Pump Power: Required Power is estimated per the following formula;
𝑸𝚫𝑯
𝑷=
𝟑𝟔𝟎𝟎𝜼
❖ Net Positive Suction Head: it is a parameter that determines the pump suction conditions
and it allows prediction of the occurrence of cavitation in the pump.
❖ Net Positive Suction Head required (NPSHr): it is dependent on the pump design; it is
established by testing the pump.
❖ Net Positive Suction Head available (NPSHa): it is the suction head minus the vapour
pressure of the liquid being pumped, therefore it is the pressure or head available above the
vapour pressure to move and accelerate the fluid into the impeller inlet.
Mathematically;

𝑵𝑷𝑺𝑯𝒂 = 𝑯𝒔 − 𝑯𝒗 − 𝑯𝒂

It is important that for any pump the Net Positive Suction Head available (NPSHa) exceeds the
Net Positive Suction Head required (NPSHr) to avoid cavitation. Cavitation is when bubbles of
vapour form in the suction line, this results in the pitting of the impeller and in the most severe
cases blowing up of the pump.

OMOARUKHE FREDRICK 38
 CHAPTER THREE
3.1 AUTODESK AUTOCAD TRAINING
During my time at DeltaAfrik, I was trained on how to use the AutoCAD. AutoCAD is very
powerful software used in the process discipline for producing Process Flow Diagrams (PFDs)
and, Piping & Instrumentation Diagrams (P&IDs).

❖ Being my first time of using the AutoCAD, with the help of my supervisor, I was able to
familiarise with the interface.

❖ I learnt how to use the draw and edit command to create basic drawings, like lines, circles,
and rectangles. I also learnt how to use layers, linetypes and colours for better presentation
of drawings.

❖ I was taught how to use the blocks and attribute command lines to produce backsheets for
project, which can be used by all disciplines during a project.

❖ I worked on many drawings, some of which are shown below:

Figure 12 Process Flow Diagram (AutoCAD)

OMOARUKHE FREDRICK 39
Figure 13 Piping & Instrumentation Diagram (AutoCAD)

Figure 14Process Flow Diagram with Backsheet (AutoCAD)

OMOARUKHE FREDRICK 40
3.2 ASPENTECH HYSYS TRAINING
This was the major training I was involved in the industry. It required me running process
simulation for oil stabilization and gas dehydration process.

The Objectives of the training was to:

❖ Give a basic understanding of the software.

❖ Application of the software.

❖ Understand the unit operations.

❖ Understand and Predict Phase behaviour of fluids.

❖ To obtain flow rate, compositions and thermophysical properties of process streams at its
various operating conditions.

❖ Understand the process of crude stabilization and gas dehydration.

❖ Use HYSYS for crude stabilization and gas dehydration process.

HYSYS is a comprehensive process modelling tool used by the world’s leading oil and gas
engineering companies, such as, DeltaAfrik, for process simulation and process optimization in
design and operations. It was developed by Aspen Technology Inc. which is a provider of software
and services for the process industry. With HYSYS, you can create rigorous steady state and
dynamic models for plant design, performance monitoring, troubleshooting, operational
improvement, and asset management.

I performed several simulation methods of condensate stabilization using HYSYS

❖ Multistage separation process by flashing method.

❖ Multiple flashes at constant pressure and increasing temperature.

❖ Multistage flash vaporization.

❖ Condensate Stabilization by using condensate stabilizer.

I also performed simulation on gas dehydration using a TEG Contactor (Distillation Column).

After my HYSYS training, I was able to understand and run process simulations for several
processes. Below are some of the simulations I carried out:

OMOARUKHE FREDRICK 41
Figure 15 Oil Stabilization; Multi-Stage Flashing (HYSYS)

Figure 16 Gas Dehydration; TEG Contactor (HYSYS)

OMOARUKHE FREDRICK 42
3.3 WORLEY PARSONS LINE SIZING SOFTWARE TRAINING
I was trained on how to size lines using the design guide of the company alongside the API 14E
sizing criteria guide. The design guide presented pressure drop and flow velocity criteria for the
sizing the lines for both onshore and offshore facilities. Generally, lines are to be sized such that
process pressure drop requirements are satisfied, and when both allowable pressure drop and
maximum velocity are shown, the more stringent of the two should govern the piping selection.

I was taught how to perform these sizing calculations manually using the formulas discussed
earlier in the pipe sizing section, after which, I manually sized several lines, both single phase lines
and two-phase lines.

I was also taught how to use the company’s spreadsheet, which already contain all the necessary
formulas in built, to perform the sizing calculations even faster.

Line sizing is a very important aspect of the process deliverables, so as to, prevent over-pressure
in lines, which may ultimately cause safety problems.

Some of the line sizing calculations I performed as captured below:

Figure 17Heat and Material Balance Sheet

OMOARUKHE FREDRICK 43
Figure 18 Line Sizing Spreasheet

OMOARUKHE FREDRICK 44
 CHAPTER FOUR
4.1 EXPERIENCE GAINED
The experiences I gained as an intern and some of the responsibility and task I was assigned has enhanced
my understanding of petroleum and gas engineering (process). I have acquired a lot of technical knowledge
of process engineering. The experiences gained can’t all be put into words, these are but a few:

❖ I was introduced to Process discipline and the safety

❖ Witnessed the preparation of some Process deliverables
❖ The Extensive use of Microsoft Excel to analyse and solve the mathematical aspect of the industry
related problems (sizing).
❖ Extensive use of Microsoft PowerPoint and Enhanced presentation skill.
❖ Interpretation of Process Flow Diagrams.
❖ Interpretation of Piping and Instrumentation Diagram
❖ Proficient use of AspenTech Hysys Software (Process simulation).
❖ Proficient use of Autodesk AutoCAD Software.
❖ Ability to carry out line/pipe sizing, such as single phase lines and two phase gas/liquid lines.
❖ Ability to think quickly and solve industrial related problems.
❖ Knowledge and good understanding of onshore/off-shore operations.
❖ Proper workplace ethics.
❖ Enhanced technical communication skills.
❖ Gained proper team work habit and orientation.
❖ Scribed for an HAZID/HAZOP session for H2S Scavenger skid Replacement Project
❖ Scribed for an HAZID/HAZOP session for an online corrosion monitoring Replacement Project
❖ Generation of Line list using Microsoft Excel.

4.2 RELATION TO COURSE OF STUDY

Table 1 RELATION TO PREVIOUS COURSES

COURSE COURSE TITLE ASSOCIATED LESSONS

CHG 201 Transport Phenomena Unit and dimensions. Pumps,
compressors, valves and piping.

OMOARUKHE FREDRICK 45
 CHG 203/CHG 204 Chemical Engineering Process Introduction to process
Analysis calculations. Heat and Material
Balance.
CHG 303 Separation Processes Something on separators and
columns.
CHG 405 Principles of Plant Design Interpretation of PFDs and
P&IDs. Appreciation of Process
design and equipment.
GEG 401 Technical Communications Writing Reports and oral
presentation
PGG 202 Introduction to Petroleum and Knowledge of Petroleum
Gas Engineering Upstream, Downstream
operations and Gas Processing
PGG 405 Petroleum Production Knowledge on oil and gas
Engineering production facilities.
PGG 409 Gas Processing Equipment Sizing of compressors, valves,
pumps and other processing
equipment.
PGG 411 Gas Dynamics Something on gas hydraulics
and Bernoulli’s equation.

Table 2 REALETION TO FUTURE COURSES

COURSE COURSE TITLE ASSOCIATED LESSONS

CHG 501 Process Dynamics and Control Understanding of Process
dynamics and controls system.
PGG 505 Gas Transportation Understanding of gas flow
through pipes. And compression
PGG 510 Gas Processes, Vessel and Design of gas compressors and
Equipment Design allied equipment.

OMOARUKHE FREDRICK 46
 CHAPTER FIVE
5.1 CHALLENGES
❖ I was not able to work on any major project since there was no new project on ground, due
to the poor economic situation of the industry.

❖ Insufficient time to gain proficient knowledge on the use of all the process engineering
software packages.

❖ Poor follow up on early payment of student allowances from SIWES.

❖ Delay in getting Log-book.

5.2 RECOMMENDATIONS
The following are some of the recommendation I suggest for the SIWES program;

❖ CILPU should provide more assistance in securing industrial attachment slots for students.

❖ Industrial training fund (ITF) should pay allowances to student promptly to facilitate
transportation and other logistics, since not all companies do pay.

❖ The information dissemination strategy with respect to things like log-book, SIWES forms
and their deadlines can also be improved on by sending emails to students.

❖ Basic computer skills like Microsoft office should be included in the school curriculum.

❖ Core software used by engineers in the industry should be introduced and taught in the
school curriculum.

❖ For the students, they should be well disposed to the training so as to acquire more
knowledge and skill in other to get better insight of life outside the tertiary institution.

5.3 CONCLUSION
My SIWES experience with DeltaAfrik Engineering Ltd was indeed very educative, enlightening,
fulfilling and completely a mind-blowing experience. It has greatly broadened my knowledge, and
I can also attest the fact that I have gained practical knowledge on the various stages in oil and gas

OMOARUKHE FREDRICK 47
production process, ranging from Crude oil Stabilization, to Gas Dehydration and Produced Water
treatment. The process engineer is a key player in carrying out these operations. The knowledge
gained from my working with several of the process engineers have broadened my view of the
industry and the role of each engineer in the optimum processing of the oil and gas.

My understanding of petroleum and gas engineering specifically in the aspect of

production/process operations has had a more practical and enlightening approach to it. This
experience also helped to broaden my understanding of certain concepts learnt in class. It is
obvious that the aim of incorporating the scheme has been accomplished to a great measure and I
have gained invaluable experiences which brings into perspective the applications of the
theoretical principles in the industry.

The SIWES programme has further exposed me to the relevance of my discipline; it has
highlighted possible areas of specialization and where further studies and knowledge is required.
I have imbibed some corporate culture and more professionalism to my discipline, including useful
managerial and organizational skills.

I am sincerely grateful for the exceptional training I has in Process Engineering and how over the
6 months, I have become more skilful in the field, more confident, and a better candidate for the
job market.

OMOARUKHE FREDRICK 48
 CHAPTER SIX
6.1 REFERENCES
❖ Mafe O.T (2015) “Guide to successful participation in SIWES” (2nd Ed.) Sodipo Press.

❖ Larry W. Lake “Petroleum Engineering Hand book Vol.3” SPE.

❖ API 14E, “Recommended Practice for Design and Installation of Offshore Production
Platform Piping Systems” (5th Ed). Jan 2013.

❖ Google.com/petrowiki

❖ Onepetro.org.

OMOARUKHE FREDRICK 49

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