CNG TRNH BY V CNG NGH NH MY X L KH GPP2 (4-6 ngy)

I/ Cc khi nim c bn trong ngnh kh 1.1 1.2 1.3 Khi nim v kh Cc sn phm kh Cu hnh chung ca mt cng trnh kh

(1 bui)

II/ Nh my x l kh GPP2 1. Cc giai on trin khai xy dng GPP2 2. Cu hnh chung ca nh my 2.1 Khu cng ngh x l kh 2.2 Khu cc h thng thit b ph tr 3. Cng ngh x l kh giai on MF 4. Cng ngh x l kh giai on GPP 5. Cng ngh x l kh giai on Modified GPP 6. Cc h thng thit b ph tr 7. Trao i su hn v thit b, kinh nghim thc t

(1 bui)

( 1,5-2 Ngy ) (1-2 bui) (1 bui) (1 ngy) (1 bui)

Lu : Nu chng trnh l 6 ngy th : Cng ngh x l kh giai on MF : 2 ngy (ngy 2 v ngy 3) Cng ngh x l kh giai on GPP: 1 ngy (ngy 4) Cng ngh x l kh giai on Modified GPP: 1 ngy (ngy 5) Cc h thng thit b ph tr: ngy 6, sng Trao i mt s kinh nghim thc t trong qu trnh xy dng GPP: ngy 6, chiu

CC NI DUNG CHNH

I/ Cc khi nim c bn trong ngnh kh 1.1 Khi nim v kh: C1, C2, C3, C4, C5+ Cng thc ha hc Kh ng hnh , kh t nhin Cc sn phm kh: Kh kh, LPG, condensate LNG, GTL, CNG Nguyn liu dng cho cng nghip ha du Cu hnh chung ca mt cng trnh kh M khai thc du (kh ng hnh), m khai thc kh (kh t nhin) ng ng dn kh: ng ng, van mt chiu, trm nn tng p, line block van Nh my x l kh ng ng dn sn phm kh: ng ng dn, ng ng cp cho cc h tiu th) Kho cha, cng xut cho tu, trm phn phi, trm np LPG cho bnh/xe bn, trm nn CNG cp CNG cho trailer

1.2

1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5

II/ Nh my x l kh GPP2 2.1 2.2 Cc giai on trin khai xy dng GPP2: MF, GPP, modified GPP Cu hnh chung ca nh my GPP Khu cng ngh x l kh Khu cc h thng thit b ph tr 2.3 Cng ngh Mc tiu Cng on Cng on Cng on x l kh giai on MF x l kh kh sn xut LPG sn xut condensate

2.4

Cng ngh x l kh giai on GPP Mc tiu Cng on x l kh kh (Nhng khc bit so vi MF) Cng on sn xut LPG (Nhng khc bit so vi MF) Cng on sn xut condensate (Nhng khc bit so vi MF)

2.5

Cng Cng Cng Cng Cng

ngh on on on on

x l kh x l kh sn xut sn xut sn xut

giai on Modified GPP: kh LPG condensate Ethane

2.6 Cc h thng thit b ph tr: Cng dng, cu hnhca tng h thng 2.6.1 H thng cp kh iu khin (Instrument air). 2.6.2 H thng cp ni t. 2.6.3 H thng cp kh nhin liu (fuel gas). 2.6.4 H thng cp hi (steam) 2.6.5 H thng cp methanol 2.6.6 H thng cp in 2.6.7 H thng Fire and Gas 2.6.8 uc v h thng x 2.6.9 H thng to mi 2.6.10 H thng lm mt (Cooling) 2.6.11 H thng lm lnh (Refrigeration) 2.6.12 H thng phng chy cha chy PCCC 2.6.13 H thng iu khin v thng tin lin lc 2.6.14 H thng nc lm mt. 2.6.15 H thng cp nc 2.6.16 H thng x l nc thi

NI DUNG CHI TIT I/ Cc khi nim c bn trong ngnh kh 1.1 Khi nim v kh: Cc ti liu tham kho: Gas Conditioning and Processing Engineering Data Book (Gas Processor Association) Naturalgas.org L hp cht hydrocarbon ch yu gm methane (C1), Ethane (C2), Propane (C3), Butane (C4), Petane (C5)+ Bng 1 70%-90%

Methane Ethane Propane Butane Pentane

Kh him

CH4 C2H6 C3H8 C4H10 C5H12 (CnH2n+2) C02 O2 H2S A, He, Ne, Xe

(Ngun Naturalgas.org)

CH4:

Kh ng hnh: L kh thot ra i km vi qu trnh khai thc du (1 tn du s km khong 200m3 kh) Kh t nhin: Khai thc t m kh (lng du t nn khai thc du khng kinh t hoc kh v mt k thut khai thc) Kh chua : kh c thnh phn CO2 , H2S cao NGL (Natural gas liquid) :C2,C3,C4, C5+

1.2

Cc sn phm kh: a. Kh kh, LPG, condensate: Kh kh: Ch yu l methane, ethane. Ty vo yu cu cng c th tch ring methane v ethane (nh trng hp modified GPP) LPG ( liquefied petroleum gas):l sn phm kh lng, thnh phn ch yu l propane v butane c gi mt mc p sut nht nh( mc p sut ty thuc vo t l C3 v C4) gi LPG dng lng trong nhit mi trng. dng hi th tch LPG tng t 200-300 ln so vi dng lng ty vo t l C3 v C4 Ty vo mc ch s dng cng c th tch ring propane v butane. Condensate: Hn hp thnh phn t v nng hn pentane (C5+) b. Mt s loi sn phm kh thng dng khc :LNG, GTL, CNG LNG (liquefied natural gas): C1, C2 gi lng -160oC. Th tch dng hi bng 600 ln dng lng GTL (gas to liquid): DME CNG (Compressed natural gas): gi lng p sut 200 bargs

c. Nguyn liu dng cho cng nghip ha du: nh trng hp sn phm ethane trong giai on modified GPP d. 1.3 Cu hnh chung ca mt cng trnh kh: 1.3.1 M khai thc du (kh ng hnh), m khai thc kh (kh t nhin)

1.3.2

ng ng dn kh: ng ng, van mt chiu, trm nn tng p, line block van

1.3.3
1.3.4 1.3.5

Nh my x l kh
ng ng dn sn phm kh: ng ng dn, ng ng cp cho cc h tiu th) Kho cha, cng xut cho tu, trm phn phi, trm np LPG cho bnh/xe bn, trm nn CNG cp CNG cho trailer

Hnh 1
M khai thc du/kh ng ng dn kh Nh my x l kh

ng ng dn sn phm kh

Kho cha, cng xut, trm phn phi

Ngi/nv s dng

II/ Nh my x l kh GPP2: 2.1 Mt s vn chung: a.Chuyn i n v : International System of Unit (SI): m, Kg, kg/cm2, 0C Imperial Unit : ft, inches,pound, psi, oF, 0K Appendix B.pdf

b.iu kin chun ca kh:

T=15oC, P=1,01325 bar Thng nht dng trong tnh ton cng ngh

c.Cc nguyn tc c bn c s dng trong x l kh :

6

1/ Tch lng kh da vo tnh cht khc nhau ca cc thnh phn kh: T trng: Cc thnh phn khc nhau c t trng khc nhau (slugcatcher). Phn nh c xu hng i ln, phn nng c xu hng i xung Nhit bc hi (boiling point):Phn nng c nhit bc hi cao hn phn nh (colum) Thnh phn kh T trng (kg/m3) (iu kin tiu chun) C1 C2 C3 C4 C5 C6 0,6785 1,2717 1,865 2,4582 3,0514 3,6477 -161,5 -88,6 -42,1 -0,48 36,04 68,74 Bng 2 2/ Phng trnh trng thi PV/T = C (kh l tng) PV=RT PV=nRT Nh vy kh dng lng c th tch nh hn dng kh. Mun gim V (ha lng) phi tng P hoc gim T L c s cho hu ht cc tnh ton trong x l, vn chuyn v tng tr kh Joule Thomson Effect dT/dP = (: J-T coefficient)... 3/Tn dng s trao i nhit ca cc dng bn sn phm/sn phm. Dng dng lnh c sn trong h thng (v d: kh sau khi gim p qua van Joule Thomson, qua expander) lm lnh i dng kh trc khi i vo cc thit b tch lng tng hiu sut thu hi lng m khng cn tiu tn thm nng lng
7

Boiling point
0

d.Kh khng c tip xc vi khng kh:

Khi tip xc vi khng kh t l nht nh (ty t l ca cc thnh phn) s to thnh hp cht gy chy n . V vy khi mun cho kh vo Bt c thit b no hoc ng ng) phi ui khng kh ra theo chu trnh: kh (hydrocarbon) ---- Kh tr (ni t) ---- Khng kh V khi mun cho khng kh vo: Khng kh---- Kh tr (ni t) ----- kh (hydrocarbon)

. Pigging:
Tt c cc ng ng vo GPP u c thit b nhn v ng ng ra u c thit b phng Pig. Tc dng ca pigging: Xy dng : lm sch ng ng Nghim thu: Kim tra ng ng : mo (Aluminium plate Pig), cc khuyt tt ca ng ng (Interligent Pig) Vn hnh : Phn m (kh/lng), kim tra ng ng, v sinh ng ng Cc giai on trin khai xy dng GPP2: Trc mt trin khai dy chuyn 1 t cng sut x l kh 10tr m3/ngy. Thi gian tip theo c theo trin khai dy chuyn 2 vi cng sut 10tr m3/ngy. Nh vy tng cng sut s l 20 tr m3/ngy. a nhanh vo khai thc, dy chuyn 1 s trin khai xy dng, vn hnh theo 3 ch : 1/Ch vi thit b ti thiu (MF-Minimum Facilities) 2/Ch GPP 3/Ch Modified GPP Sau mt thi gian ngn vn hnh ch MF s hon thnh v a vo s dng ch GPP. V LPG c hiu qu kinh t cao hn kh kh v thng khi khng tch ht c phn lng th trong giai on tip theo lng ny cng s c tch tip v t burn pit ti cc trm phn phi kh gy lng ph. Sau ty theo yu cu ca th trng s tch Ethane

MF Kh kh Thu hi mt phn LPG Condensate

GPP Sn phm ca nh my Kh kh Thu hi LPG Condensate

Modified GPP Kh kh Thu hi LPG Condensate Ethane Bng 3

2.2

Cu hnh chung ca nh my GPP

Khu cng ngh x l kh: Bao gm cc phn chnh sau:

H thng sn xut kh kh H thng thu hi LPG H thng n nh condensate H thng thu hi Ethane H thng tch CO
2

H thng tch nc

Khu cc h thng thit b ph tr

Cc h thng thit b ph tr: Cng dng, cu hnhca tng h thng H thng cp kh iu khin (Instrument air). H thng cp ni t. H thng cp kh nhin liu (fuel gas). H thng cp hi (steam) H thng cp methanol H thng cp in H thng Fire and Gas uc v h thng x H thng to mi H thng lm mt (Cooling) H thng lm lnh (Refrigeration) H thng phng chy cha chy PCCC H thng iu khin v thng tin lin lc
9

H thng nc lm mt. H thng cp nc H thng x l nc thi 2.3 Cng ngh x l kh giai on MF

Cng on x l kh kh:
Sn phm: kh kh, P=59barg, T=600C, nhit im sng:thp nht 50C. Nhit im sng (dew point) ca hydrocarbon: nhit mi trng thp nht m hydrocarbon lng khng th hnh thnh c di iu kin p sut t 24-38 barg (p sut vn hnh ca ng ng). Kh t ng ng vo GPP2 vi p sut 70 barg, nhit 170C. u vo GPP2 c lp by-pass thit b nhn pig (V-1001 Sphere Receiver). Sau kh vo Slugcatcher (Z-1002): ti y tc di chuyn ca kh b chm li, phn kh c t trng nh hn s di chuyn ln u trn ca Slugcatcher (upper header). Phn lng nng hn di chuyn xung u di ca Slugcatcher (lower header). Nh vy lng c tch ra da vo t trng khc nhau ca lng v kh.

10

Hnh Slugcatcher

Kh t u trn ca Slugcatcher sau i vo V-1201 (gas filter/separator) c lc v tip tc tch lng. Nguyn tc tch cng da trn t trng.

11

Hnh Gas Filter/Separator

Kh sau c i qua thit b trao i nhit E-1202 (warm gas/gas exchanger). Ti y kh u vo c nhit cao c kh nh V-1203 (Warm Separator) lnh hn (sau khi qua Refrigeration Package/Joule Thomson Valve) lm lnh i t nhit mi trng xung ch cn T= 50C tng hiu sut tch lng cho giai on tip theo (kh cng dng lng khi nhit cng thp). Kh tip tc i qua Refrigeration Package/Joule Thomson Valve X-1205 A/B. p sut sau ch cn 59 barg, nhit cn 0,20C. Sau kh c a vo bnh tch V-1203 (Warm Separator). Ti y phn kh nh s i ln nh ca bnh tch, phn lng nng hn s i xung y v s tham gia vo cng on thu hi lng (LPG v Condensate).

12

Kh phn nh bnh tch l kh thnh phm (Sale Gas) do c nhit thp hn (do kh i qua Refrigeration Package) s c a qua E-1202 lm lnh kh u vo (nh trnh by trn) ng thi c kh u vo lm nng ln trc khi ra khi nh my a v Ph M. Trn ng ng kh kh ra khi nh my c lp by-pass Sale Gas Pipeline Pig Launcher V-1804 phc v on ng ng t y ln Ph M. Ngoi ra tng thu hi kh kh (v c sn phm lng) s c mt cng on nng cao hiu sut thu hi kh kh v sn phm lng c trnh by sau phn cng on sn xut Condensate - xem phn (*)

Cng on thu hi LPG:

Sn phm LPG, P=12 barg, T=640C Phn lng : - u ra thp (Lower Head) ca Slugcatcher - y ca Gas Filter/Separator V-1201 Vo bnh tch Wet Deethanizer Feed Drum (V-1102). Phn kh ra pha trn V-1102 vn cn thnh phn C1, C2 nn s tham gia vo cng on nng cao hiu sut thu hi kh kh v sn phm lng c trnh by trong phn (*) Phn lng ra pha di y V-1102 c lc qua thit b lc (Filter F-1101). Sau chia lm 2 nhnh vo thp tch (Wet Deethanizer V-1104). Nhnh u khong 30% vo khay trn, nhnh th hai vo khay di, nhnh th hai trc khi vo thp c a qua thit b trao i nhit Wet Deethanizer feed bottom exchanger (E-1103). T l mi dng v v tr c th ca tng khay s do tnh ton thp quyt nh. Ti E-1103 dng lng th hai trc khi vo thp c dng thnh phm LPG t y thp Stabilizer (c qua thit b gia nhit reboiler E-1705 nn c nng ln) lm nng ln khong 1520C v vy n khng cn vo thp t khay trn v gim c cng sut gia nhit ca Reboiler E-1105.

13

Thp tch: Lm vic da trn nguyn tc cc thnh phn kh khc nhau c im si (boiling point) khc nhau. Nhin chung thp tch thng c cc thit b i km l thit b gia nhit (Reboiler) y thp sc hi nng ln, bm hi lu (Reflux Pump) bm lng (cn li nh thp) quay li thp tip tc tham gia qu trnh tch. Bn cha lng ca bm hi lu (Reflux Drum). Dng lng cn tch thnh phn nh ra khi thnh phn nng hn c a vo thp tch chy t khay trn xung khay di gp dng kh nng do Reboiler cp nhit) bay ln, nhng va p ny tch phn nh ra khi phn nng v bay ln. y l qu trnh xy ra lin tc trong thp, phn nng s tch t ti y thp, phn nh s bay ln nh thp.

14

Hnh 2 Cu hnh thp tch

15

16

Shell Tube Reboiler

17

Lng hi lu H s hi lu = -----------------(cn gim h s ny) Lng tch c Thp tch Wet DeethanizerV-1104 khng c bm hi lu v ch c Reboiler. Vo thp Wet Deethanizer V-1104 ngoi hai dng lng t V-1102 cn c dng th 3 l dng lng y V-1203 vo thp khay trn cng vi dng th nht. Kh nh thp Wet Deethanizer V-1104 (19 barg, 570C) s tham gia vo cng on x l nng cao thu hi kh kh v sn phm lng lng (*).

18

Hnh Wet Deethanizer V-1104

Lng tch t y thp tch Wet Deethanizer c thnh phn l C3, C4 v C5+ (19 barg, 1760C )s c a sang thp tch Stabilizer V-1701 tip tc tch ring thnh LPG v Condensate. Thp tch Stabilizer V-1701 c y cc thit b i km (Reboiler, Reflux Pump, Reflux Drum). nh thp Stabilizer l thnh phm LPG (12 barg, 640C) , nu bn cha LPG V2201 A/B cha xy dng xong s c a thng ra LPG Metering M-2203 ri a ra ng ng LPG vn chuyn v Th Vi. Trn ng ng LPG ra khi GPP2 c lp By-pass Pig launcher V2204. Khi bn cha LPG V2201 A/B xy dng xong sn phm LPG s c chuyn v bn, sau chia lm 2 ng hoc c Bm LPG P-2202 A/B bm ra ng ng thp tch LPG v Th Vi hoc c bm LPG P-2211 A/B bm ra trm np xe bn.

19

Cng on sn xut condensate

Sn phm Condensate C5+ (12,5 barg, 2070C ) c tch t y thp Stabilizer s c a qua thit b trao i nhit E-1103 lm nng kh u vo thp tch Wet Deethanizer a dng kh ny ln 1520C(nh trnh by trn), ng thi c dng kh u vo ca Wet Deethanizer lm ngui bt i dng sn phm Condensate. Dng sn phm Condensate cn c tip tc lm mt xung cn 500C khi i qua thit b lm mt E-1106 Condensate Cooler. Sau hoc c chuyn vo b cha Condensate T-2301 A/B ri bm Condensate P2302 A/B bm ra ng ng Condensate hoc a thng ra ng ng Condensate. Trn ng ng Condensate ra khi nh my Condensate s c o ti Condensate Metering M-2303 v c lp By-pass Condensate pipeline Pig Launcher V-2304

Cng on x l nng cao hiu sut thu hi kh kh v sn phm lng (*):

Kh nh Wet Deethanizer V-1104 (19 barg) cn thnh phn C1, C2 Nn c nn ln 2 cp (First stage, Second stage) t p sut u vo nh my (70 barg) v a v u vo V-1201 (Gas Filter/Separator) x l li, nng cao hn t l thu hi kh kh v sn phm lng. Trc khi v li V-1201 Kh sau my nn (c nhit cao) c a qua thit b trao i nhit Condensate Heater E-1114 lm nng phn lng u ra y V-1203 (trc khi vo V-1104) Mi cp nn s gm cc thit b sau: Compressor Scrubber: (V-1107, V-1111) nu cn phn lng s c tch ra, kh vo my nn (compressor) s l dng kh. My nn: C-1108 A/B (Wet Gas Compressor First Stage), C-1111 A/B (Wet Gas Compressor Second Stage). Thit b lm mt (Wet Gas Compressor Cooler)

Cng on x l ph phm:
Thng thng trong nh my mi cng on u c thit b kim tra cht lng sn phm trc tip (Online gas sampling). Nu sn phm khng t yu cu ( bt c u trong nh my) s c thu gom v V-2221 Offspec Bullet v Bm P2222 A/B Offspec Pump bm v u vo V1102 x l li.
20

2.4

Cng ngh x l kh giai on GPP Mc tiu so vi MF : Nng cao hn hiu sut thu hi LPG; Lm ngt kh:Loi 60% C02 (C02 Removal) Tch nc (Dehydration)

Cng on x l kh kh (Nhng khc bit so vi MF):

Kh sau khi ra khi u trn ca Gas Filter/Separator V1201 trc khi i qua E1202 s qua cng on x l C02 (C02 Removal) v tch nc (Dehydration). Sau khi qua E-1204, kh vo Warm Separator V-1203 (nh MF). Trong giai on ny van kim sot p sut gia E-1202 v V-1203 c b qua (by-passed). Kh ra nh V-1203 (trong MF l thnh phm kh kh) th trong GPP c tip tc x l qua cng on lnh (cold section) s chia lm 2 dng. Dng th nht i qua phn Expander ca Turbo-Expander CC-1406, nhit s c h t -8 0C xung cn 65 0C ri i vo thp Rectifier V-1407 pha di thp. Dng th hai (-80C) s i qua Gas/Gas Exchanger E-1401 trao i nhit vi dng kh ra t nh ca Rectifier (-810C) c lm lnh i cn -78 0C (ng thi dng vo thp ny cng lm nng ln dng kh kh ra nh Rectifier -810C) sau qua Joule-Thomson van nhit h xung -106 0C ri vo Rectifier khay pha trn. Dng vo Rectifier cn mt dng th ba t nh NGL Recovery Column V-1501 (s trnh by chi tit phn sau) c nhit -58 0C. Nh vy kh kh thnh phm ra nh Rectifier s c nhit l -81 0C. Lng y Rectifier c Rectifier Bottom Pump P-1408 A/B bm vo khay pha trn ca thp NGL Recovery Column V-1501. Trc khi vo thp dng ny c a qua thit b trao i nhit NGL Recovery Column Condensor E1502 c dng ra nh ca V-1501(30C) lm nng ln (thp NGL Recovery c vai tr tch C1, C2 ra khi C3, C4, C5+ nn nhit cn cao ch cn C3, C4, C5+ tch t di y), ng thi dng ny lm ngui i dng kh ra nh ca V-1501 trc khi quay li V-1407. NGL Recovery Column c vai tr nh Deethanizer.
21

Kh kh ra nh ca Retifier V-1407 (16 barg, -810C) c lm nng ln qua trao i nhit ti E-1401 v E-1202 v nn ti my nn ca Turbo-Expander CC1406. Sau kh kh thnh phm li c nn chuyn vo ng ng a v Ph M (By-pass c Pig Launcher). Cm nn kh kh u ra GPP cng gm Srubber V-1801 A/B/C, my nn C-1802 A/B/C v Cooler E-1803 A/B/C nn cho p yu cu. Lu : Mt phn kh u ra ca phn nn ca CC-1406 c tch ra phc v

cho vic ti sinh thp Dehydration. Kh ny s b t sau khi phc v ti sinh s c lm mt nc ngng t v loi b nc tr thnh kh kh v li np vo ng kh kh pha trc cm nn ca CC-1406.
CO2 Removal: CO2 nu gp nc s to thnh H2 CO3 l cht n mn S hin din ca CO2 cn lm cho nhit tr ca kh gim i (2%-3% gim nhit tr khng ng k). C th c vn ( nh hnh thnh CO2 dng cng) khi gp nhit thp trong NGL Recovery. Trong hp ng bn kh ca British Gas Max CO2 l 2% (ng ng khng b n mn p sut max 70 barg). Phng php hp th (Absorption) c s dng loi b CO2, dng loi dung dch amin c bit. Mt s loi Amine c s dng: MEA Monoethanolamine (low pressure) Dng cho c H2S v CO2 DEA Diethanolamine (high pressure) Dng cho c H2S v CO2 MDEA Methyldiethanolamine (hp dn H2S hn CO2 ) Ngoi ra cn mt s hp cht pha trn khc.

22

S n gin qu trnh hp th

Kh t u ra pha trn ca Gas Filter/Separator V-1201 i qua thit b trao i nhit E-1915 (Gas Recuperator) vo thp hp th Absorber V-1902 tip xc vi amine. Kh ngt ( c loi b CO2 ) ra nh Absorber V-1902 sau khi qua E-1915 s vo Overhead Filter/Separator V-1903 loi b amine (b cun theo) cn li trc khi a sang thit b tch nc. Lng (rich amine-amine hp th CO2) ra u di ca Overhead Filter/Separator V-1903 s c gim p v a n u vo ca Flash Drum V-1904. Hydrocacbon cn li s c

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tch ra V-1904 v i ln pha trn ca V-1904 cp vo h thng p thp ca Fuel Gas. Lng ra pha di Flash Drum s i qua Amine Filter F-1916 ri i qua trao i nhit Lean/Rich Exchanger E-1905 v vo Thp ti sinh Regenerator V1906. Thit b gia nhit Reboiler E-1907 s lm nng tch CO2 ra khi amine. CO2 ra nh Regenerator s qua Condenser E-1908 nc ngng t v CO2 c x ra ng x (vent) Lng ra y thit b gia nhit ca Regeneration l amine sch ( loi b CO2) c lm mt ti trao i nhit E-1905 v Circulating Pump P-1911 A/B bm v Absorber sau khi qua mt t lm mt na E-1912 v bm chuyn tip P-1913 A/B. Amine c b sung t Amine Drain Drum V-1917 bng bm Amine Drain Pump P-1918 Sau cng on loi b C02 l cng on: Tch nc (Dehydration): Khi c s hin din ca nc, trong iu kin nhit thp nht nh phn t hydrocarbon v nc s to thnh tinh th (hydrates) s lm tc ng ng (nht l loi c ng knh nh), nh hng n hot ng ca h thng iu khin. Ngoi ra nc cn l cht n mn nht l khi c s hin din ca CO2 . Phng php p dng: hp ph (Adsorption), s dng Molecular Sieve v: C th t c t l nc cn rt thp C th dng cho nhiu loi thnh phn kh (High selectivity, vd:poor selectivity: Active Alumina/silica gel nu hp ph Hydrocarbon nng th khng th x ra c desorbed) tch nc C 3 loi cht hp ph chung nht: Active Alumina Silica Gel
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Molecular Sieve (3A, 4A, 5A, 10X, 13X) C 3 thp V-1301 A/B/C): 2 thp hp ph v 1 thp ti sinh. Kh sau khi qua cng on CO2 removal s vo pha trn thp hp ph (2 thp), gp Molecular Sieve v qu trnh hp ph xy ra. Kh kh ra khi thp pha di c lc (bi) qua F-1304 sau a sang V-1202 (MF/GPP). Qu trnh ti sinh thp: khi Molecular Sieve bed no nc th chuyn thp sang ch ti sinh gm 5 bc : 1.Gim p (depressurization) 2.Gia nhit (heating nc bay hi ra) Heater 3.Lm mt thp (cooling) Cooler 4.tng p (pressurization) 5.Ch ch (standby) tip tc chy ch hp ph.

25

Mt lng kh kh c trch ra phc v qu trinh gia nhit, my nn Circulation Compressor C-1302 A/B nn li ri a qua thit b gia nhit Regeneration Heater H-1303, kh nng vo thp (qu trnh ti sinh) t pha di v bc t di ln c lm mt ti Dryer Regeneration Cooler E-1305 v a vo Dryer Regeneration Knockout Drum V-1306. Kh ra nh V-1306 c a v ng Sale Gas, lng y c a v Flash Drum (cng on CO2 removal) x l li.

(Trnh by Dehydration ca GPP Bch H tham kho)

26

Nhng khc bit so vi MF:

MF 1/ 2/Warm Separator Column V-1203 3/ GPP CO 2 Removal Dehydration Warm Separator Column V-1203 Rectifier ColumnV-1407 NGL Recovery V-1501Column Expander CC-1406

Cng on sn xut LPG (Nhng khc bit so vi MF)

T u vo nh my cho n khi lng chia thnh 2 dng vo Wet Deethanizer V1104 ging nh MF. Trong MF u vo Wet Deethanizer cn 1 dng na l lng t y Warm Separator th trong trng hp GPP th dng ny c a v NGL Recovery Column. Lng t y Wet Deethanizer c a sang Stabilizer V-1701 nh MF Vo Stabilizer cn 1 dng na t y NGL Recovery Column. Trc khi vo thp dng ny c trao i nhit ti E-1706 Stabilizer Feed/Bottom Exchanger v c dng kh y Stabilizer lm nng ln. Thnh phn ra nh Stabilizer l thnh phm LPG nh trong MF

Cng on sn xut condensate (Nhng khc bit so vi MF)

Sn phm Condensate ra y Stabilizer nh trong MF. Ch khc l khi ra khi thp c trao i nhit E-1706 (thay v E-1103 nh trong MF)

Cng on x l nng cao hiu sut thu hi kh kh v sn phm lng:

Ging nh MF

27

2.5

Cng ngh x l kh giai on Modified GPP:

Cng on x l kh kh
Kh ra nh Warm Separator V-1203 nhnh i vo pha y ca Rectifier s qua mt cng on lm lnh (thay v qua Expander nh trong GPP) p ng yu cu tch Ethane. Tham gia vo cng on ny c : Kh t nh Warm Separator c a qua thit b trao i nhit E-1402 c lm lnh i khi trao i vi dng lnh ra y Cold Separator V-1405; sau c tip tc lm lnh hn ti Chiller E-1404 (lm lnh bng propylene refrigerant), cng on lm lnh cui cng ti Gas/cs liquid Exchanger E1403. Kh ra nh Cold Separator V-1405 c a qua Phn Expander ca CC-1406. T y dng kh s nh ch GPP.

Cng on sn xut LPG

Dng vo pha trn Stabilizer thay v t y ca NGL Recovery (GPP) trong giai on ny l dng t y ca Deethanizer V-1601. Cn li nh GPP.

Cng on sn xut condensate

Dng vo pha trn Stabilizer thay v t y ca NGL Recovery (GPP) trong giai on ny l dng t y ca Deethanizer V-1601. Cn li nh GPP.

Cng on sn xut Ethane

Dng lng ra y NGL Recovery thay v v Stabilizer (GPP) trong giai on ny c a sang Deethnizer V-1601. Ethane ra nh thp ny c a qua Deethanizer Condenser E-1602 (Chiller), Deethanizer Reflux Accumulator V1604. Sau my nn Ethane Booster Compressor C-2002 nn ra ng ng Ethane. Tm Tt phn cng ngh x l kh: Trong GPP2, thu hi lng c thc hin bng 3 phng php lnh sau: 1.External Refrigeration; 2.Joule Thomson Expansion; 3.Turbo-Expansion.

28

Ch yu bng phng php 2 v 3 v p ng cc iu kin: p sut ca kh cao (High pressure gas); Dng kh ln (High gas flowrate); Yu cu cht lng kh thnh phm cao (Severe sale gas specification): nh thu hi C2+ Khi thu hi lng p dng cc phng php lnh c th xy ra cc hin tng: To Hydrates; To CO2 dng cng (solid) Cn c cc bin php x l cc vn ny: Dehydration CO2 Removal

29

MT S VN CHI TIT 1/ BLEVE B L E V E Boiling Liquid Expanding Vapour Explosion

Bin php: Gim thiu thit hi nu c xy ra hin tng BLEVE: Bullet khng cha thng vo Control Room, cc thit b quan trng Ngt ngay ngun gy chy : ng van li H thng phun nc t ng lm mt thit b Cc bin php khc cha chy

2/ Flammability/Explosive Limits

Methane - C1 Ethane - C2 Propane - C3 Butane C4 Pentane C5

Low Limits LFL / LEL (% vol/Vol Air) 5 / 5,3 2,9 / 3,2 2,1 /2,4 1,8 /1,6 1,4 / 1,4

High Limits HFL / HEL (% vol/Vol Air) 15 / 14 13 / 12,5 9,5 / 9,5 8,4 / 9,5 8,3 / 7,5

30

Auto-Ignition Limits: C1 C5 : 516 0C 309 0C

3/ Safety Shutdown System (SSD):

Unit Shutdown (USD) Process Shutdown (PSD) Emergency Shutdown (ESD)

Cp bo v 3 Cp bo v 2 Cp bo v 1

PSD : c th ch shutdown 1 cm thit b

SDV

Safety Shutdown Valve

ESDV Emergency Shutdown Valve 4/ H thng x Nu thit b khng cn an ton : qu p hoc b trc trc cn phi x. Khng c x ra mi trng (nu c th) v phi x ra uc t (kh), ra Burn pit t (lng) (Relief System) Pressure Relief: Cch ly thit b (ng cc van cch ly) sau x qua Pressure relief valve hoc qua Rupture disk. High Intergrity Process Protection (HIPP) gim thiu lng x (nu x qu nhiu) Blown Down: C mt s van Blown down (GPP Bch H: 8) x qua h thng iu khin trong phng iu khin trung tm .

5/ Phn vng nguy him (IP - 15): Zone 0 : Thng xuyn c cht chy hoc cht chy c trong thi gian di

31

Zone 1 : Thnh thong c cht chy trong hot ng thng xuyn Zone 2 : Trong hot ng bnh thng t khi c cht chy hoc nu c ch trong thi gian ngn.

6/ B tr vi nc hoa sen trong khu thit b: Ti nhng ni c methanol hoc ha cht khc: nu b vng vo c th c th ra ngay. 6/ H thng kim sot p sut, nhit , dng, mc : (Pressure, temperature, flow, level) Pressure Controller Temperature Controller Flow Controller Level Controller PC TC FC LC - - - - Pressure Control Valve Temperature Control Valve Flow Control Valve Level Control Valve PCV TCV FCV LCV

PIC: TIC: FIC: LIC:

Pressure Indicator Controller Temperature Indicator Controller Flow Indicator Controller Level Indicator Controller

32

33

34

2.6

Cc h thng thit b ph tr: Cng dng, cu hnhca tng h thng 2.6.1 H thng cp kh iu khin (Instrument air). 2.6.2 H thng cp kh nhin liu (fuel gas). 2.6.3 H thng cp hi (steam) 2.6.4 H thng cp methanol (Methanol Supply) 2.6.5 H thng cp Ni t 2.6.6 H thng in (Power) 2.6.7 H thng Fire and Gas 2.6.8 H thng uc v x (Flare and Relief) 2.6.9 H thng phng chy cha chy PCCC (Fire Fighting) 2.6.10 H thng nc lm mt. (Cooling Water) 2.6.11 H thng cp nc 2.6.12 H thng x l nc thi 2.6.13 H thng to mi (Odorant) 2.6.14 H thng lm lnh (Refrigeration) 2.6.15 H thng qut lm mt 2.6.16 H thng iu khin v thng tin lin lc

35

2.7.1 H thng cp kh iu khin (Instrument air) Phc v cho kch hot (ng m) ca cc van iu khin (IA) :PCV, TCV, LCV Trong vn hnh/bo dng sa cha (Process Air-PA):blowing, Pressure testing (nu th thy lc khng ph hp) Dng cho sn xut ni t. Kh iu khin phi kh, sch (khng c du, m) p sut vn hnh 10 barg (thit k 1200 KPa, 70 0C) Air compressor Package C-3001 A/B/C Wet air Receiver V-3002 Instrument air Receiver V-3003 Instrument air Dryer Z-3004 A/B/C Mainline Filter F-2305 A/B/C After Filter F-2306 A/B/C UFD

(S n gin v tay)
2.7.2 H thng cp kh nhin liu (fuel gas). Phc v cho cc tucbin, ng c (my nn, my bm) chy bng kh: Gas engine/turbine generator Dng nh la cho uc (flare) v hm t (burn pit) Cp nhit : Dehydration Regeneration Heater, utility boilers Thi uc-Purge Flare (trong trng hp h thng ni t trc trc) Ly t ngun kh GPP2 p sut : Ty vo i tng s dng, c th ly t p sut cao hoc thp trong nh my. HP Fuel Gas Scrubber V-3201 SG Compressor Filter F-3202 A/B SG Compressor Heater E-3203 A/B Regenerator FG Filter F-32044 UFD

(S n gin v tay)

36

2.7.3 H thng cp hi (steam) Dng gia nhit: Steam c dng nhiu nht sau n hot oil (dng ti GPP Bch H) v th 3 l nc nng (tt cho mi trng, SNC-Lavalin xut trong FEED cho GPP Bch H).

p sut Vn hnh X l nc Tui th thit b Kim sot nhit Mt nhit X (blow down) Chi ph u t

Bng so snh Steam Boiler v Hot Oil Heater Steam Hot Oil Cao (nguy him) 0 barg hoc cao hn mt cht Cn (t) Khng cn Ngn hn (c n mn) Di hn (khng c n mn) 0 ln hn 0,5 C 0,5 0C Nhiu hn t Mt lin tc Khng cn R hn t hn

Nu nhit cn cp nm trong khong 0 0C 180 0C nn chn steam hoc nc. V trn 180 0C p sut hi tng rt nhanh cn cu trc chc hn (chu p lc cao). p sut hi cao HP: p sut hi thp LP: p sut thit k: Utility Boiler B- 3400 A/B/C Deaerator V-3401 24 barg, 224 0C 4 barg, 151,9 0C 25 barg, 250 0C

(S n gin v tay)
2.7.4 H thng cp methanol (Methanol Supply) CH3OH Tc dng: -Ngn nga to Hydrates: ti nhng cng on x l c nhit thp, nu c thnh phn nc s kt hp vi hydrocarbon to thnh cu trc tinh th lm tc ng (nht l cc ng nh), lm cc thit b iu khin khng hot ng chnh xc c. Khi bm methanol vo s h c nhit to Hydrate xung.
37

-Ph hy cc hydrate to thnh. Methanol Storage V-3901 Methanol Pump P-3902 A/B

(S n gin v tay)
2.7.5 H thng cp Ni t: Vn hnh: X lin tc ra uc khng kh khng lt c vo h thng qua uc. Lm lp m pha trn bn cha methanol. Bo dng, sa cha : Purging (thi kh ra) thit b trc khi m ra bo dng sa cha v thi khng kh ra khi a thit b tr li vn hnh. Nu cng sut khng phi cp ni t bnh. Ni t 6-7 barg GPP Bch H s dng PRISM Nitrogen Membrane System (G5000)

38

Nguyn l hot ng: Da vo nguyn tc cc cht kh khc nhau c tc ngm qua mt loi mng lc (polymer fibers) khc nhau. u im: gi r 1/20 1/30 Ni t bnh Nhc im : tinh khit khng cao lm (chp nhn c trong ngnh kh 99%) H thng gm (Bch H) u vo l IA Nitorgen Generator: Membrane, 100 m3/h t 99% N2 buffering vessel 2.7.6 H thng in (Power) Chy my bm, my nn, qut lm mt cng nghip (Air fined Cooler) v mt s yu cu khc trong vn hnh nh cp nhit, phc v cho mt s phn iu khin Chiu sng (n chng chy, n) Chng st (Tip t cho thit b) Ngun chnh : do my pht chy bng kh cp. Ngun d phng: T in li, qua trm bin p 22/6,6 KV v 6,6/0,4 KV My pht chy bng diesel Li trung p (6,6 KV) v h p (0,4KV)

39

2.7.7 H thng Fire and Gas y l h thng rt quan trng v pht hin sm s gip ngn chn c cc nguy c chy, n hoc cc iu kin nguy him khc H thng Fire Detectors, Gas Detectors B tr ti cc v tr c nguy c kh b r r, nguy c chy/n Fire Detector: La chn da trn cc hin tng xy ra khi c chy nh: Tng nhit (Thernostatic detector-TS, Thermodifferential detector-TD, Thermovelocimetric detector-TV) Khi (Ion detector-khi v kh chy lm thay i dn ca khng kh ion ha) Kh chy (nh trn) C ngn la (Optical detector: ultra-violet detector-UV, infra-red detector IR) Gas detector: Fix and portable Mt s ni c bit khng c php c kh chy c (flammable gas) l: Phng iu khin trung tm (k c ngun ly khng kh vo) Trm in t trong nh my Phng phn tch (analyser houses) My nn khng kh u vo kh nhin liu ca gas turbine u khng kh vo v ra ca gas turbine V tr t: Theo tiu chun; Phi tnh ton ring cho tng thit bda trn cc nguyn tc nh: Phi gn ni c nguy c xy ra; Ty vo t trng m t cao hn hoc thp hn: nu nh hn khng kh th phi t cao hn im c kh nng xy ra cc hin tng v ngc li; Hng gi chnh Khi pht hin ra c chy hoc c r r kh :

40

Nu ch c mt detector pht hin r r trong gii hn thp c th ch pht bo ng trong phng iu khin v bo ng nhn thy c bn ngoi khu thit b Khi c mt hoc vi detector pht hin r r mc cao c th s t ng shutdown cm thit b , t ng kch hot h thng phun nc. T ng phun bt (b cha condensate, LPG) ngn hydrocarbon tip xc vi khng kh v x vo closed drain a ra burn pit) 2.7.8 H thng uc v x (Flare and Relief) L h thng thit b an ton chnh ca GPP. t an ton phn kh x ra t cc van x p an ton (PSV pressure safty valves,), cc hng x (vent), khi blown down Ton b kh trn c a vo Flare knockout drum: phn lng a ra hm t ( burn pit) t, phn kh t uc. Flare c th purge bng ni t hoc fuel gas (d phng trong trng hp h thng ni t c trc trc) Flare c nh la t ng (in), c thit b gia nhit (heater) ha kh liquid a t flare v khi blown down nhit Flare knockout drum rt thp (ng bng) cn c lm nng (heat up)

(S n gin v tay)

2.7.9 H thng phng chy cha chy PCCC (Fire Fighting) NFPA a.H thng nc cu ha: B cha:Phi cha lng theo tiu chun (ngng cp vo b phi cp lng cp b cng theo tiu chun) Bm:2 bm b p, 1 bm ly tm (in/diesel) ng ng:chy quanh khun vin nh my, lp cc u ch phc v m rng nh my. C lp cc hng phun c nh cch nhau ti a 40m

41

Hng ly nc :trong khu cng ngh, t dc ng ni b cch thit b ti a 60m, c t cha ng mm, u ni, kha b.H thng phun nc t ng (water spray) c.Trang thit b cha chy ban u: vn hnh bng tay nh bnh CO2, bnh bt, bnh bt

d. H thng cha chy khc: X C02 trong phng kn (phng iu khin :khi ton b nhn vin ra ngoi ht) 2.7.10 H thng nc lm mt. (Cooling Water): Lm mt cc ng c: my nn, tuc bin, my nm, my iu ha cng nghip hoc thit b lm lnh (refrigeration) Phc v cho cc Condensers, coolers (lubricating oil coolers) Nc lm mt c s dng thng dng nht trong cc GPP H thng kn (closed system) gi nhit ca nc lm mt thp hn nhit mi trng so vi h thng h v gi khng cho cc vt th khc ri vo. X l ha cht: Pha cht Chng n mn (anticorrosion); Chng to cu bn (antifoulants) Chng to rong ru (Biological control)

2.7.11 H thng cp nc Nc sinh hot Sn xut nc lm mt Cp nc cu ha Cp cho cc thit b ph tr: vi ra b tr trong khu thit b c ha cht

(S n gin v tay)
2.7.12 H thng x l nc thi B t hoi X l nc du: b CPI
42

UFD

(S n gin-v tay)
2.7.13 H thng to mi (Odorant System): Cho cht to mi vo sn phm (Sale Gas,LPG) nu c r r s d dng pht hin C mt s loi sn phm : Mercaptane, Sulfide Bch h : Mercaptane H thng gm cc b phn chnh sau (Bch H): Bn cha (20 gallon, 20 ngy) Bm (Injection Pump chy bng IA) Thit b kim sot tc bm (Injection Rate Controller) Ngoi ra cn h thng bo ng (Alarmodor)Report

43

2.7.14 H thng lm lnh (Refrigeration) Trong cc Chillers Dng propylene (refrigerant) v: -Hiu qu hn Propane (Propane ca GPP khng tinh khit, nu mun s dng phi x l tip) -Propylene thng mi c sn trn th trng Vit Nam.

S lm lnh 2 cp -1 chiller (v tay)

44

2.7.15 H thng iu khin v thng tin lin lc H thng SCADA:

45

ICSS (PCS-Process Control System, SDS-Safety Shutdown System, FG-Fire and Gas) H thng thng tin lin lc v tinh/ VSAT PCS iu khin: Cc qui nh thng thng
46

Qui trnh tun t cho tt c cc qu trnh SDS gim st cc thng s c kh nng l mi nguy him cho ngi, thit b, mi trng.Tn hiu u vo 4-20 mmA. FGS Gim st vic d la, r r kh mi nguy him cho ngi, thit b, mi trng.Tn hiu u vo 4-20 mmA. u d nhit, la, kh ICSS s kt ni vi Cc gin ngoi khi qua v tinh VSAT Kho cng Th Vi bng cp quang FOC GPP NCS 1 FOC Terminal NCS1 FOC Trm tip b (LFS) foc v RTU Line Block Valve FOC v RTU Ph M GDC FOC v RTU 2.7.16H thng qut lm mt Phc v hot ng ca cc Cooler Air Fin Coolers

Cc h thng khc:

47

MT S VN CN LU TRONG THIT K, LP T, NGHIM THU V A THIT B VO S DNG: 1/ H thng NCR (None Conformance Reports): Ton b qu trnh sau c ghi nhn trong mt mu c nh s th t Cc bn ghi nhn li: cc bn A v B k xc nhn; Bn B (nh thu) lp phng n sa cha li. Bn A k duyt; Bn B thc hin sa cha li, c s chng kin xc nhn cng vic sa cha c thc hin; Th trng bn A (Ch mt ngi duy nht c xa li-Site Manager) k xc nhn qu trnh sa cha li c thc hin xong- close out NCR).

u im ca phng php: Theo di y (c nh s, nht k cng trnh c th cn b st li :ch cn b gim st theo di); C th dng nh gi nng lc ca nh thu trong cc cng trnh tip theo (nu t NCR l nh thu cht lng).

2/ Tun th cc yu cu ca : Thit k c ph duyt; Cc tiu chun c lin quan; Cc qui trnh (lp t, nghim thu, chy th) c ph duyt; Cc yu cu v khuyn co ca nh ch to thit b: Cc thit b thng c nh ch to cung cp km cc ti liu hng dn. Cn c k v tun th y ; Ngoi ra cn cn tun th cc phng thc thc hin chung (Common Practice)

Cc bn xc nhn li vi nhau phi cn c vo cc ti liu trn 3/ An ton Intrinsically Safe An ton ton din gm: Thit k cng ngh an ton
48

Thit k thit b an ton H thng kin tra an ton K thut ngn chn tn tht (trn c 3 bc sau: ngn chn cc hin tng bt bnh thng, ngn chn cc trng hp s c khn cp v ngn chn tai nn )

An ton ngay c khi xy ra: C ngi mum nn ngun la vo (khng th vo c khu vc c cht d chy). Khng b hoc ngi in

49

50