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DR Engp M II p1 1.1 R.5grifado
DR Engp M II p1 1.1 R.5grifado
PART: I Topside
CHAPTER: 1 Process
CORPORATE INFORMATION
OFFSHORE PRODUCTION FACILITIES ENGINEERING GUIDELINES Rev. 5
VOLUME II BASIC DESING GUIDELINES
Part.I Ch.1Sec.1.1 General Crit. For Platform Processing Plant Page 2 of 176
INDEX
1. PURPOSE .................................................................................................................................. 7
3. GENERAL .................................................................................................................................. 8
3.1. Process Plant......................................................................................................................... 8
3.1.1 Required Fluid Data for Design Basis ............................................................................... 8
3.1.2 Treated Fluids Specifications ............................................................................................ 8
3.1.3 Number of Separation Stages and Operating Pressure/Temperature Selection ............... 9
3.1.4 Oil Process Plant Design Configurations .......................................................................... 9
3.1.5 Gas/condensate Process Plant Design Configurations ................................................... 13
3.1.6 Equipment Sizing for Configurations 1, 2, 3 and 4 .......................................................... 16
3.1.6.1 Degassers ...................................................................................................................... 18
3.1.6.2 Free Water Separator ..................................................................................................... 18
3.1.6.3 Production Separators .................................................................................................... 18
3.1.6.4 Electrostatic Treater (TO) ............................................................................................. 18
3.1.6.5 Atmospheric separators .................................................................................................. 19
3.2. Additional Requirements ...................................................................................................... 19
9. COMPRESSION SYSTEMS..................................................................................................... 35
9.1. General ................................................................................................................................ 35
9.2. Waste Heat Recovery Units (WHRUs)................................................................................. 36
9.3. Cooling Water System ......................................................................................................... 36
9.4. Depressurization .................................................................................................................. 37
9.5. Compression Units Condensate Destination ........................................................................ 37
1. PURPOSE
The purpose of this document is to describe the General Criteria for Processing Plant Design
applicable to the Basic Design of Offshore Production Units.
2. REGULATORY REFERENCES
The standards mentioned in the text are listed below. In addition, DR-ENGP-I-1.1 Standards and
Technical Regulations Used in Projects shall also be used.
NRs Regulation Standards of the Ministry of Labor
API RP 14C Recommended Practice for Analysis, Design, Installation, and Testing of Basic
Surface Safety Systems for Offshore Production Platforms
OIML-R120 Standard Capacity Measures for Testing Measuring Systems or Liquids Other
than Water
API 4 API MPMS Chapter 4
API STD 617 Centrifugal Compressors for Petroleum, Chemical, and Gas Service
Industries
API STD 619 Rotary Type Positive Displacement Compressors for Petroleum, Chemical,
and Gas Industry Services
API-MPMS 10.4 Manual of Petroleum Measurement Standards
ANP 128 de 08.28.2001 Specification of National or Imported Natural Gas for Domestic
Trade
API-STD-521/ ISO 23251 Guide for Pressure-Relieving and Depressuring Systems
API STD 2000 Venting Atmosphere and Low-Pressure Storage Tanks
BS EN 12874:2001 Flame Arresters Performance Requirements, Test Methods and Limits
for Use
AGA No. 3/ No. 9 Orifice Measurement of Natural Gas
AGA No. 7 Measurement of Fuel Gas by Turbine Meters
AGA No. 8 Gas Compressibility and Super Compressibility
ASTM D4057 Standard Practice for Manual Sampling of Petroleum Products
ISO 3170 Petroleum Liquids Manual Sampling
CONAMA 393 Produced Water Disposal Regulation
DR-ENGP-I-1.6 Guidelines for Oil and Natural Gas Measurement Systems
3. GENERAL
The process plant design configuration shall be selected among the different alternatives described
in itens 3.1.4. and 3.1.5.
In order to achieve a proper design and a functional process plant, the following basic information is
essential:
Representative fluid PVT compositional analysis (more than one, if available);
Production curve prediction (oil/gas/water and/or gas/condensate/water) together with related
wellhead and Stationary Production Unit (SPU) incoming pressure prediction over lifetime;
Minimum and maximum flow rate for each process step (compressors included) or unit;
Shut-in pressure, highest and lowest Stationary Production Unit (SPU) incoming pressure and
temperature in operation for each producing well, for the different production phases;
Estimated lift gas demand over time (pressure and flowrate), when applicable;
pressure and temperature achieved on topside gathering system after a shutdown period, for
each well;
Oil physical properties (viscosities at three different temperatures, wax deposition temperature
(TIAC), API specific gravity, cloud point and asphaltene deposition tendency);
Gas contaminants contents (CO2, Hg, H2S and other sulfur compounds, aromatic and nitrogen
compounds, where applicable);
Note: Heat and Material Balances issued by Basic design shall contain the expected contaminants
contents for all streams, including oxygenated compounds content (TEG/MEG/ethanol) and
benzene;
Characterization of formation water and of the water produced in formation tests (if any);
Stationary production unit (SPU) general characteristics.
Treated oil Basic Sediment & Water (BSW), salt content, Reid Vapor Pressure (RVP),
temperature to storage tanks or to export;
Treated gas to be exported, injected and used as lift gas or fuel contaminants contents,
water dew point, hydrocarbon dew point;
Treated condensate to be exported or to be stored in cargo tanks Reid Vapor Pressure
(RVP), temperature, water content;
Treated water to be discharged or injected solids content, oil-in-water content, temperature,
pressure and others, according to items 6 and 16 in this document.
The operating pressures of the separation stages shall be selected based on reservoir
characteristics and expected wellhead pressures during production lifetime.
For gas/condensate and high GOR oil fields, reservoir studies shall be presented for different
topside back-pressures, taking into account the possibility of two different production phases, due to
the field pressure drop. These studies shall be performed to select the best configuration and
Design Basis shall indicate if two production phases (high pressure / low pressure) have to be
considered as part of the scope.
The pressures for the subsequent stages shall be chosen according to process/compressors
optimization and standardization and taking into account any other intermediate process units
required to treat the produced gas (hydrocarbon dew point and contaminants removal).
The temperature at the 1st stage of separation shall be adequate to allow proper phases separation;
heating shall always be considered. This is also required for gas/condensate fields, and the
possibility of parafin formation shall also be taken into account.
The selection of temperatures for oil processing shall be based on:
laboratory tests for gravitational separation at the 1st stage.
laboratory tests for electrostatic oil treatment. These tests shall be carried out with and without
dilution water.
The incoming production fluid shall be heated. Whenever possible, the inlet fluid shall be blended
with high temperature produced water from 2nd and 3rd stages, at 1st stage separator inlet. Heat
st
exchangers shall be avoided upstream the 1 separator. During early production phase, when
produced water is not present yet, oil shall be used as the heating fluid to the blend, using the same
piping circuit. In the case of gas/condensate fields, different configurations are possible.
Figure 1 Configuration 1
Figure 2 Configuration 2
Figure 3 Configuration 3
Figure 4 Configuration 4
Figures 5, 6 and 7 describe general process schemes for a gas/condensate offshore process plant,
with different condensate destinations (pipeline or cargo tanks). Figures 6 and 7 include a main
compression step.
The dimensions, diameter and tangent-to-tangent lengths presented on Table 1, shall be used for
the vessels in the design of oil separation and treatment plants. The dimensions and the number of
trains to be selected for each oil treatment stage shall be defined according to the criteria described
in this table.
3.1.6.1 Degassers
For cases with a maximum liquid production of 150 000 bpd, for the degassers of Configuration 2
(with settling tank), a 3.7 x LTT 11 m degasser train shall be provided.
For cases with maximum liquid production of 150 000 bpd to 300 000 bpd, two 3.7 x LTT 11 m
trains shall be provided. Alternatively, one 4.3 x LTT 16 m degasser train may be used.
The dimensions of 4.3 x LTT 19 m shall be adopted for the free water separators of Configuration
1 (with desalting) and configuration 3 (without desalting).
The number of production trains shall be the same as the number of electrostatic separation trains.
For cases with maximum liquid production flowrate up to 200 000 bpd, one or two production trains
shall be used, depending on the number of electrostatic treatment trains selected. For cases with
liquid production flowrate between 200 000 bpd and 300 000 bpd, two production trains shall be
used for the free water separators, production separators and electrostatic treatment units.
For maximum liquid production flowrates up to 200 000 bpd, one 4.3 x LTT 19 m production
separator train shall be used in case only one electrostatic treatment train is selected. If two
electrostatic treatment trains are required, then two 3.7 x LTT 13 m production separators trains
shall be used.
For liquid flowrates between 200 000 bpd and 300 000 bpd, two 4.3 x LTT 19 m production
separator trains shall be used.
The dimensions of ( 4.3 x LTT 15 m) or ( 4.3 x LTT 22 m) are the only ones allowed for the pre-
TO and TO. The number of pre-TO trains shall be the same as the number of TO trains. The
number of trains of the free water separator and production separator shall also be the same as the
number of TO trains.
The selection of one dimension among the options on Table 1, for the pre-TO and TO, shall be a
function of the possible treatment temperature and of the flowrate, both of which depend on the flow
and type of oil to be processed. The flowrate for the pre-TO and TO shall be lower or equal to the
maximum allowed flowrate for each treater.
For sizing the pre-TO and TO, initially an operation temperature lower or equal to 100C shall be
tested. If the dimensions and the number of trains exceed the values available on Table 1, a
temperature lower or equal to 120C shall be tested. If the dimensions and the number of trains are
still exceeding the values available on Table 1, a temperature up to 130C shall be allowed, which
will require the use of special materials for the vessels.
The dimensions of 3.7 x LTT 11 m shall be adopted for the atmospheric separators. For oil
flowrates up to 100 000 bpd, one train shall be adopted.
For cases with maximum oil production up to 100 000 bpd, for the atmospheric separators of any oil
treatment plant configuration, one atmospheric separator train shall be adopted.
For cases with maximum oil production of between 100 000 bpd and 300 000 bpd two atmospheric
separator trains shall be adopted.
The control valves of liquid/gas/water separation systems shall be sized considering production
curve prediction.
For the early production phase, when the wells start producing in a sequence, and not all of them at
the same time, the use of split-range valves or valves with interchangeable internals shall be
considered in order to allow CV changing.
In case of FPSOs and Floating Systems, the influence of the vessel movements shall be taken into
account for the design of equipment.
For the automatic valves, such as SDVs and XVs, Basic Design shall choose between internal
equalization or the installation of manual equalization valves; each case shall be individually
analyzed. If it is necessary to install the equalization valve, it shall attain the same safety
requirements of the main valve (fire safe, etc.), and shall remain locked closed.
Two safety relief valves shall be installed in all main vessels and equipment that operate
continuously, one as backup of the other, with easy and visual identification of the position of each
one.
The inner diameters of connecting risers (gas exportation, gas lift, gas injection), usually following
API standards, shall be compatibilized with Unit topside piping, usually ANSI B31.3 standards, in
order to avoid restrictions for pigging operations (conventional, ball or instrumented).
All piping systems which require pigging shall be clearly stated in Design Basis documents.
Design Basis shall state, besides the shut-in condition, the highest and lowest incoming pressure
and the highest and lowest incoming temperature for each well in the platform, for steady flowing
conditions and for restarting production after a shutdown period, as well as the specific piping
location these data are related. Topside piping and fittings material downstream well chokes shall
be specified to the minimum temperature achieved downstream the depressuring device,
considering restart after a well shutdown period.
4.1. General
Facilities for pigging all the flowlines coming from the Wet Christmas Trees (WCT) of producing
wells or subsea production manifolds shall be provided, even if the flow assurance studies do not
indicate the possibility of organic deposits formation in the production lines.
The facilities for pig displacement shall be designed for the use of gas and diesel.
When the use of flex tube is indicated, facilities at each well flowline incoming shall be provided,
before the first bend, in order to allow this kind of operation for each well.
Basic Design shall determine hydrates formation envelope for each well production line, to make
sure that the operating conditions of all wells (normal flowing and shutdown) are out of the hydrates
formation region. If hydrates are likely to occur under flow, some hydrate prevention method shall
be applied.
The alternatives to be considered are:
hydrate inhibitor continuous injection upstream of each wellhead choke;
gathering fluids at high pressure, avoiding subsea depressurizing devices and JT effects. In
this case, wellhead choking is located at topside facilities, allowing inhibitor injection control
improving and minimizing emulsion effects.
In order to prevent hydrates formation during restart production after a shutdown period, facilities
shall be provided to allow depressurizing the segregated gas accumulated in the production line to
the test separator and the gas from gas lift line to flare system. This operation is to be performed
only after shutdown, and shall not be automatic. Basic sizing criteria (time required to depressurize
each line) shall be defined during Basic Design.
For gas/condensate wells, if hydrates are likely to occur during normal flowing conditions or upon
production restarts after shutdown, the same considerations and hydrate prevention methods
presented previously shall be applied.
The 1st stage high pressure separator shall be designed considering the wells flow pattern and
possible liquid hold-up formation upstream the platform.
The test separator shall be designed considering the flow pattern of each individual well and
possible liquid hold-up formation upstream the platform. A test heater shall be provided, upstream
of test separator.
When the platform receives and processes gas from other platforms, a system consisting of a
dedicated header and slug catcher vessel shall be assessed. The size of the slug catcher shall
guarantee a stable operation of the process plant and shall be based on liquid holdup in the pipeline
during pigging operations, received continuous liquid flowrate, operational procedure and slug
control devices.
Facilities shall be provided to allow diesel and treated oil from cargo tanks injection to fulfill the
flowline after relieving procedure through the gas lift line or service line.
Quick connections with valves for well killing in the annulus lines of the wells shall be provided.
The diesel service system shall comply with any opening requirements of subsurface safety valves
(SSSV) or downhole safety valves (DHSV).
A pressure indicator upstream the positive and adjustable chokes and on each production and test
header shall be provided. In order to track the temperature of the incoming fluid, a temperature
transmitter upstream each choke valve and also pressure and temperature transmitters downstream
each choke valve shall be provided. The PTs and TTs shall be installed in locations that will not
hinder pig passage. Facilities to inject hot diesel (maximum 90C) upstream of each production
choke valve shall also be provided for the wells with high tendency of wax deposition.
For production wells, a digital downhole pressure and temperature transmitter, PDG (permanent
downhole gauge) or equivalent, shall be provided whenever possible, at the discretion of Reservoir
Engineering.
PTs with indication in the Supervisory System shall be installed in the annuluses of production wells,
when gas lift is applied.
The choke internal material, for wells producing from non consolidated rock fields without gravel,
shall have sufficient hardness to withstand high abrasion (tungsten alloys).
Local PDIs shall be installed in the hot and cold streams of the heat exchangers. Pressure and
temperature indications upstream and downstream of each heat exchanger stream shall be
provided in the Supervisory System, directly (close to the heat exchanger) or indirectly (located at
another equipment, such as pump, compressor, vessel, separator etc.).
Provide an individual bypass for each heat exchanger to allow for cleaning and maintenance.
Depending on specific applications, Basic Design may select plate heat exchanger (PHE), printed
circuit heat exchangers (PCHE) or shell and tube heat exchangers.
When using plate type heat exchangers, facilities shall be provided for diesel flushing, in order to
replace the fluid in case of shutdown, preventing organic deposition inside the plates. Basic Design
shall determine the best type of protection in order to avoid contamination of the process plant with
the Diesel System, preferably using a dedicated system.
Sampling points (try-cock valves) shall be installed along the shell height of separator vessels (free
water K.O. drum, test and production separators and electrostatic oil treaters), in the region of
water-oil interface.
Lines shall be provided for depressurizing and/or draining filters and FQIs operating with liquid
hydrocarbons, routing them to the collectors of atmospheric vents and open oily liquid drains.
Spectacle blinds shall be provided in all inlets and outlets connections larger than 4, in order to help
equipment maintenance.
For fields with expected sand production, Basic Design shall provide a connection for a sidestream
system in the separator vessels for removing sand and sediments.
A spool shall be installed, individually per production train, close to and upstream the block valve of
the first separator vessel, to allow future installation of a slug damping valve, if necessary. Spare
analogic automation connections, one pair per each production train, shall be provided in the input /
output (I/O) panel closest to the site. If there is the expectation of occurrence of slugs should be
provided the use of band control to level control of separator vessels of production.
Whenever there is an indication that the fluids to be processed present foam formation tendency,
the installation of cyclonic separation devices at the inlet of the separators shall be considered for
foam breaking.
The connections for anti-foaming injection shall be located as far as possible from the separator, in
order to maximize contact time.
a) Installation of pig receivers/launchers in production lines and oil pipelines. A study shall be
carried-out to define the number of wells per receiver;
b) the production lines of the wells coming from the pig receivers shall be routed to the test
separator and production separator as well;
c) facilities for paraffin inhibitor injection in the Wet Christmas Tree (WCT) shall be provided;
d) facilities for application of N2 Generation System (SGN). In this case, a temperature of
o
100 C shall be considered for all the specifications of surface equipment, lines and
accessories, including the turret swivel, when adopted.
These facilities include:
2 connections (chicksan connection WECO 1502) connected to one permanent and
dedicated line from the bunkering station to be tied into to the discharge of the service
pump;
temperature measurement in the return from the SGN (kerotest type connection or
thermometer) at the arrival/inlet of the separators;
mooring of stimulation vessel from where the SGN shall be mixed and pumped;
e) connection at the arrival of the risers for SGN operation by flex tube;
f) if rigid polyurethane pigs are to be used, the inner diameter of the production riser (or gas
lift line) shall be compatibilized with the production (or gas lift) lines of the Unit.
A foam breaking cyclonic device shall be installed with bolts to allow easy removal for maintenance.
Devices for mist removal from the gas phase shall be installed, either the knitted wire mesh or the
cyclone type or a vane-type device. Facilities shall be provided to allow these internals removal for
cleaning purposes .
Anti-vortex devices of the cross plate type shall be installed at the oil and water outlet lines.
Wave breaker devices shall be assessed for floating platforms and ships.
The test separator shall be three-phase type, with metering systems provided for all phases; this is
also valid for gas/condensate fields Units.
The test separator shall be designed considering the flow pattern of each individual well and
possible liquid hold-up formation upstream the platform.
A test heater shall be provided, upstream the test separator.
The test separator gas outlet piping shall be connected to the low and high pressure relief system,
with pressure control (PC/PV), in order to allow the test separator to operate at very low pressures.
FQIs shall be installed downstream of the test separator pumps in order to avoid cavitation, in case
intrusive instruments are used. The FQIs shall be installed downstream of the FV, avoiding
repeated oil metering, and upstream of the LV, avoiding the acceleration of the meter by the gas
released at this valve, in order to avoid inaccurate metering and possible damage to the FQI.
An online BSW analyzer shall be provided at outlet oil line. After metering, the oil shall be pumped
to the process plant, upstream pre-heating exchanger and water shall be pumped to water
treatment plant.
Whenever arrangements are needed for fiscal metering calibration, the provisions of
DR-ENGP-I-1.6 Guidelines for Oil and Natural Gas Measurement Systems shall be considered.
The acceptable technologies are AC electrical field (vertical and horizontal flow), combination of AC
and DC (AC/DC) electrical field and Variable Frequency electrical field.
High velocity technologies, i.e., technologies that introduce the emulsion directly or close to the
electrodes zone, only will be accepted if the BSW at treater inlet is lower than 20%, will be not
acceptable for pre-treater (the first stage of dehydration). In this case, the charge for this treater
shall be stable, i.e., with no flow variation.
Additional water outlet nozzles shall be provided for future expansions of the system. Devices to
prevent vortex at water outlets shall be installed.
For sampling, 05 (five) try-cocks shall be installed at the interface zone.
For each treater using Single AC Technology, AC/DC Technology or Variable Frequency
Technology, one spare transformer shall be supplied for each installed transformer. The spare
transformers shall be assembled on the vessel, ready to operation.
In special cases where each oil treater has 3 (three) transformers AC Technology, 4 (four)
transformers with delta-star configuration shall be supplied, each one sized for 33% of demand
(3 X 33%). The 3 transformers with delta-star configuration shall be assembled on the vessel. The
back-up transformer shall be assembled as a spare part, to be stored in the warehouse.
Two 100% pressure safety valves (PSVs) shall be provided and installed in the bushing duct
between each transformer and the vessel.
For AC and AC/DC technologies, the transformers shall have transformers with series reactors for
limiting short-circuit current at secondary to the value of rated secondary current. A no-load oil
immersed tap changers shall be provided at secondary winding. The tap changer operation shall be
possible externally, with the tank closed. Each operating transformer shall be provided with one
pilot-lamp, in parallel with the voltmeter, to work as a field indicator, showing that the transformer is
operating properly or not.
In order to prevent transformer insulation oil from contamination and in order to prevent corona
effect, it shall be provided effective sealing methods and leakage detection. For each bushing duct
between each transformer and vessel remote leakage alarm shall be foreseen, turning off the oil
treater in case of alarm.
Transformer tank, tap changer and secondary terminal boxes shall have oil level indicators. A local
panel with voltage and current indicators and a transformer circuit breaker shall be installed on
primary cycle of entrance transformer to isolate it from power supply during vessel maintenance. It
shall be furnished with a locker device on open and closed position.
The entrance bushings and Insulators shall be made of resin with field proven application for similar
service. The resin shall be brand new, no reprocessed resin shall be used. The material of entrance
bushing and insulators shall be made of compression process.
The equipment data-sheet provided by Basic Design shall require from manufacturer:
resin certification tests: X-ray, specific mass and penetrating tests for entrance bushing and the
insulator facilities to allow entrance bushing maintenance from vessel external side without the need
for vessel internal access
Provide a safety margin between the required and the available NPSH of at least 1 meter for the
transfer pumps.
A stand-by shall aways be provided to booster and main pumps and the final configuration shall be
analyzed case by case, as a function of the Unit and of the expected production curve.
When the total head of the pumping system is over 50 kgf/cm2, the head shall be better distributed
between the booster and main pumps, in order to allow low flow oil transfer operations with only the
booster pumps on duty (main pumps off). This situation occurs at early production phase and during
start-ups after shutdowns (wells gradually getting back to operation) and at the end of well
production life (oil production decline with increasing BSW).
For satellite platforms, the possibility of not using atmospheric separators and pumping oil not
st
stabilized from the 1 stage separators directly to the oil pipeline shall be assessed. The final
stabilization will be performed at a central platform, where the low pressure gas will be gathered.
A BSW meter shall be installed in line in sections of vertical piping with upwards flow, in the export
line, downstream transfer pumps and upstream level control valve of the atmospheric separator.
The oil storage and transfer temperature shall be set up as a function of the maximum allowable
operating temperature of the storage tanks and offloading systems (in case of FPSOs) or as a
function of the design temperature of the export riser and the crude oil cloud point (TIAC). In
cases subject to overheating, high temperature alarms shall be installed to protect the weakest
system.
If no other specifications are clearly stated in Design Basis, treated oil to be stored in tanks shall be
cooled so that its Reid Vapor Pressure (RVP) is lower or equal to 10 psia, ensuring total stabilization
of the oil (this RVP restriction is still valid when gas condensate is incorporated to the oil in the
tanks). Oil shall also be specified for BSW 0.5 %, salinity 285 mg/L (95 ptb) and H2S 1 mg/kg.
The BSW analysis shall comply with API-MPMS 10.4; the salinity analysis shall comply with ASTM
D3230; the H2S analysis shall comply with UOP 163-89 and ISO 6326-3.
A network of remote actuated valves shall be installed for oil distribution to the cargo tanks, so that
tank filling is independent of tank discharging and cleaning operations.
Routing hydrocarbon volumes directly to cargo tanks without fiscal metering is not acceptable; this
requirement also includes any recovered oil volume and condensate streams from H.P Flare K.O
Drum, L.P Flare K.O Drum, Closed Drain (if applicable), overflow (oil stream) from hydrocyclone,
overflow (oil stream) from the flotation unit, overflow (oil stream) from slop tanks and others.
Shall be provided facilities for treated oil utilization, already specified according item 5.4, for hydrate
prevention in flow lines. In case of well closure (scheduled or not scheduled), the design shall
consider the facilities available for treated oil circulation (oil system interconnection with the service
system, accessories, heating, etc.) shall be available for immediate use. Diesel utilization for this
purpose shall still exist as an alternative to oil treated which shall be the base case. Shall be
evaluated the need mixture of diesel and treated oil as well as the necessity of heating the oil. Shall
be foreseen measuring devices for oil flow in order to determine the volumes used. Shall be
evaluated the feasibility of using a system of fiscal measurement, considering the risk of ANP
(National Agency of Petroleum, Natural Gas and Biofuels) not to approve the discount oil used (as
fiscal measurement) of the volumes produced tax if if using a measurement system operational.
6.1. General
The disposal of produced water shall comply with the Regulation CONAMA-393.
In order to comply with the maximum oil in water content allowable as defined in CONAMA-393,
several configurations of the following equipment shall be assessed: hydrocyclones, flotation unit,
nut shell filters, multimedia filters and centrifuges.
The overflow of the hydrocyclones and flotation unit and the oily waste from filters shall be routed to
the Recycle Vessel or to any process vessel that can store this flow. Centrifuges can be used to
treat this stream. In this case, the oil shall be mandatorily routed back to process plant and water
stream back to water treatment plant.
The hydrocyclone batteries shall have flexibility for distribution of the feeding stream, in order to
receive the 1st stage separator and the electrostatic treater through a segregated header for each
separation train. The water inlets from the 1st stage separator and electrostatic treater shall be
located at opposite ends of the hydrocyclone header, with valves to allow the distribution of the
number of dedicated liners for each vessel.
The treated water shall be discharged after treatment directly overboard in cases with no injection of
produced water is considered. The disposal of produced water shall be carried out by a dedicated
piping system or a caisson, segregated from drainage system. The produced water disposal piping
end shall be located below the sea surface.
If this configuration is not used, the margin to be adopted in the capacity of the hydrocyclones
dedicated to the electrostatic treaters shall be assessed during Basic Design.
The dissolved gas in the produced water will be released downstream the LV of the production
separators, generating large gas bubbles. The need for removing this gas bubbles by a degasser
vessel or directly in the flotation unit shall be assessed.
The water stream from the test separator shall be connected upstream oil heating system or to the
free water separator or first stage degasser.
Control of the hydrocyclone overflow rate, by means of differential pressure ratio shall be provided
by the Process Control System.
The hydrocyclones inlet header shall be accessed for internal cleaning.
The liners shall be arranged by groups. The selection of one or more groups to operation shall be
done without opening the vessels.
Isokinetic connections shall be provided for sample collecting at the water outlet of the free water
separator, electrostatic treaters, inlet and outlet of the hydrocyclones and flotation unit, outlet of
degasser vessel and inlet of the caissons or open drain tanks.
An online TOG analyzer shall be provided in the produced water disposal line. The acceptable
technologies are laser induced fluorescence and light scattering. In cases where the oil phase will
be composed exclusively of gas condensate, the light scattering technology shall be preferred. The
system shall have facilities for automatic lens cleaning and sample conditioning.
The oily water inlet line of each hydrocyclone shall be interconnected to the overflow by means of a
pipe equipped with a ball type block valve, for back-washing operations.
The flotation unit shall be the dissolved gas type or hydraulically induced. Sparger type flotation
units shall not be used.
The minimum residence time at the flotation unit shall be 10 minutes.
One or two FPSO cargo tanks, to be defined on Design Basis, shall be designed to be Offspec
Tanks. These Offspec Tanks receive offspec water and offspec oil streams, due to any temporary
plant malfunction or equipment out of service. The minimum capacity of each one shall be
10 000 m and they shall be fully coated and specified according treatment plants operating
conditions.
Fluids from Slop Tanks may also be routed to Offspec Tanks.
After a certain residence time, the phases tend to segregate and both separate phases (oil and
water) shall be routed back to corresponding process plant. The other water streams, i.e., water for
tightness testing of hoses, hose washing water, tank washing water, tank scraping water, shall be
routed to Slop Tanks.
The capacity of the Slop Tanks shall be as defined in item 5.6 of the DR-ENGP-II-P2-2.2 General
Criteria for FPSO-FSO Hull Systems Design, in compliance with the minimum of 5 000 m for each
tank (dirty slop and clean slop).
All these tanks that shall handle produced water and segregated water shall be prepared for
corrosive environment and shall be provided with facilities for controlling the generation of H2S.
Sensors for H2S shall be installed in confined areas containing piping handling water from the Slop
Tanks and from the Offspec Tanks of the vessel.
7. DRAIN SYSTEM
7.1. Definitions
Closed drain the drain coming from equipment in operation, handling hydrocarbons, with no
contact with air; (e.g. drainage of pockets in suction lines of compressors, drainage of fuel
gas filters, relief valves discharge pipes, etc.)
Open drain Gravity Drains from sources at atmospheric pressure, such as open deck drains,
drip pan drains, and rain gutters.
Hazardous open drain a drain coming from drip pan and gutters of equipment installed in
classified areas;
Non-hazardous open drain a drain coming from drip pan and gutters of equipment installed
in non-classified areas;
Hazardous hydrocarbon open drain drains coming from points with frequent hydrocarbon
drainage, such as sampling points of oil and produced water, transfer pump skids, pig
launcher and receiver skids, etc.
Non-Hazardous hydrocarbon open drain drains coming from workshops, laboratory, diesel
system.
The following figure presents the configuration of the drain system for each SPU type.
7.2.1 General
No communication shall be allowed between the vessel bilge system and the plant drain system.
During the design of open and/or closed drain lines on semi-submersible platforms, determine the
possibility of oil return from the headers to the gutters and/or equipment due to the vessel
movements (roll, pitch, and heave) and the small slope of the headers.
Provide the system with an open hydrocarbon drain tank, and direct the drain from the open
hydrocarbon drain header into this tank. The liquid of this tank shall be pumped to the
process.
Helideck refueling skid drainage shall be directed to that header.
The open hydrocarbon drain tank shall be provided with a siphon in the inlet line, in order to
direct the overflow to the caisson in case of a very high level condition in this tank.
The hazardous hydrocarbon open drain header shall be provided with liquid seal and piping
submerged in the open hydrocarbon drain tank.
Direct the open drain from the classified areas to the classified area caisson.
The Hazardous open drain header shall be sized for serving the area where the water flow to
the deluge system is the largest among those foreseen by design. Add the hydrant flow to the
above flow.
In order to avoid oversizing the caisson from classified areas, in case of deluge or strong
rains, the exceeding flow shall be directed overboard.
Direct the open drain from non-classified areas to the non-classified area caisson. The Non-
hazardous open drain header shall be sized for serving the area where the water flow for the
deluge system is largest among those foreseen by design. Add the hydrant flow to the above
flow.
In order to avoid oversizing the caisson from non classified areas, in case of deluge or strong
rains, the exceeding flow shall be directed overboard.
The drain from the diesel oil system, from non classified areas, may be directed to the raw
diesel tank, if gravity flow is possible, or to a specific atmospheric tank, which shall also
receive the drains from the laboratory hood and workshops. From this tank, the liquid shall be
pumped to the open hydrocarbon drain tank. This specific atmospheric tank shall be provided
with a vent to a safe location.
The Non-hazardous hydrocarbon open drain header shall be sized for serving the area where
the water flow to the deluge system is the largest among those foreseen by design. Add the
hydrant flow to the above flow.
In order to avoid oversizing the caisson from non classified areas, in case of deluge or strong
rains, the exceeding flow shall be directed overboard.
Provide siphon drains with removable baskets for cleaning, and sufficient area for liquid flow.
Whenever possible, use gutters for floor drain. The siphons shall be flanged to allow easy
removal for cleaning.
The installations shall not have closed drains for maintenance of equipment. For these cases, the
drain shall be directed by means of flexible hoses to the open drain system of the area.
Only in case of units handling poisonous substances at critical concentrations, (e.g. sour gas
containing H2S 10 ppmv), the maintenance and instrument drains shall also be connected to a
hazardous contaminated closed drain system. For background information, refer to API RP 55,
Recommended Practices for Oil and Gas Producing and Gas Processing Plant Operations Involving
Hydrogen Sulfide.
Drainage for maintenance operations - except in case of poisonous substances - shall not be
connected to closed drain systems. Special care shall be taken to ensure that closed drains shall
not be used for depressurizing equipment prior to draining.
All hose nozzles shall have block valves with blind flanges.
All closed drain nozzles shall have two block valves with blind flange.
7.3.1 General
No communication shall be allowed between the bilge system of the vessel and the drain system of
the plant.
When designing open and/or closed drain lines for FPSOs and FSOs, ensure that no oil will return
from the collectors to the drains and/or equipment due to vessel movements (roll, pitch, heave, trim
and heel) and the small slope of the collectors.
Inside the turret, when receivers/launchers or equipment handling hydrocarbons are included, a
system for collecting drainage from the Hazardous Hydrocarbon Open Drain shall be provided.
The liquid recovered in the Hazardous Hydrocarbon Open Drain tank of the turret shall be directed
to the manifold located in the turret.
The installations shall have no closed drain for maintenance of equipment. In these cases, the drain
shall be directed with flexible hoses to the open drain system of the area.
Only in case of units handling poisonous substances at critical concentrations, (e.g., sour gas
containing H2S 10 ppmv), the maintenance and instrument drains shall also be connected to a
hazardous contaminated closed drain system. For background information, refer to API RP 55,
Recommended Practices for Oil and Gas Producing and Gas Processing Plant Operations Involving
Hydrogen Sulfide.
Drains for maintenance operations except in case of poisonous substances shall not be
connected to closed drain systems. Special care shall be taken to ensure that closed drains shall
not be used for depressurizing equipment prior to draining.
All hose nozzles shall have block valves with blind flanges.
All closed drain nozzles shall have two block valves with blind flange.
The Hazardous Hydrocarbon Open Drain shall be directed to the dirty slop tank of the vessel.
The liquid from this tank shall be pumped to the process.
Provide the hazardous hydrocarbon open drain header with liquid seal and piping submerged
in the slop tank. Helideck refueling skid drainage shall be directed to that header.
The Hazardous Open Drain shall be directed to the dirty slop tank of the vessel. The liquid
from this tank shall be pumped to the process.
Provide the hazardous open drain header with liquid seal and piping submerged in the slop
tank.
The Hazardous open drain header shall be sized for serving the area with the largest water
flow to the deluge system among those established by design. Add the hydrant flow to this
flow.
In order to avoid oversizing the open drain system of classified areas, in case of deluge or
strong rains, the exceeding flow shall be directed overboard.
The Non-Hazardous Open Drain shall be directed to the dirty slop tank of the vessel. The
liquid from this tank shall be pumped to the process.
Provide the non-hazardous open drain header with liquid seal and piping submerged in the
slop tank.
The Non-hazardous open drain header shall be sized for serving the area with the largest
water flow to the deluge system among those established by design. Add the hydrant flow to
the this flow.
In order to avoid oversizing the open drain system of non classified areas, in case of deluge or
strong rains, the exceeding flow shall be directed overboard.
The drain of the diesel oil system, from non classified areas, may be sent to the raw diesel
tank, if gravity flow is possible, or to a specific atmospheric tank, which shall also receive the
drains from the laboratory hood, workshops and skid for helideck fueling. From this tank, the
liquid shall be pumped to the dirty slop tank of the ship. This specific atmospheric tank shall
be provided with a vent into a safe location.
The Non-hazardous hydrocarbon open drain header shall be sized for serving the area with
the largest water flow to the deluge system among those established by design. The hydrant
flow shall be added to the deluge flow.
In order to avoid oversizing the open drain system of non classified areas, in case of deluge or
strong rains, the exceeding flow shall be directed overboard.
Provide a siphon drain with removable baskets for cleaning and sufficient area for liquid
drainage. Whenever possible, gutters for floor drainage shall be used. The siphons shall be
flanged to allow easy removal during cleaning.
7.4. Caisson
Fixed platforms shall be provided with flanges, in the compartment of the caisson pump, in order to
adjust the oil interface height to the level variations due to jacket installation.
Provide manhole in the caisson.
Provide sample collection in the discharge lines of the classified area caisson pump and in the drain
tanks with water/oil separation.
The installation of a vessel for oil recovery from pressurized gas (blow case vessel) shall not be
allowed for replacing the caisson pump in case of pump failure.
The gas from free water separators, production separators, test separator and Vapor Recovery
Units (VRUs) shall be gathered and may be routed to a common gas header. Basic Design shall
evaluate which streams need cooling. A Safety K.O. drum shall be provided, downstream the
header, with capacity to gas maximum flow rate, regardless compressors configuration and other
scrubbers included in compression packages.
Basic Design shall evaluate recovering gas streams resulted from eventual depressuring
operations, such as lift gas header, wells annulus release, export pipeline and any equipment at the
process plant, by routing them to a proper gas system in the platform, according to pressure and
temperature conditions of each stream.
9. COMPRESSION SYSTEMS
9.1. General
Process Data Sheets to be submitted to manufacturers shall include all necessary design cases
with compositions, including contaminants such as H2O, CO2, H2S and other sulfur compounds,
minimum and maximum flow rates, inlet pressures and temperatures and required discharge
conditions.
All compression systems shall comply with the item referring to compressors of
DR-ENGP-M-II-P1-2.2 Turbo-Machinery Requirements.
Shutdown Valves (SDVs) at gas inlet and outlet of each compressor package shall be provided, as
well as at the scrubbers condensate outlet pipings, in order to isolate the machine. In case of gas
treatment units between compression stages, basic design shall evaluate the need of installing
additional SDVs.
A scrubber vessel shall be provided at the suction of each compression stage.
A final aftercooler shall be provided for each compressor package.
For compressor packages materials specification purposes, ISO 15156 shall be mentioned as a
requirement and the H2S content shall be specified in Design Basis and compressors Data Sheet.
The compressors shall be designed to have pressurized and depressurized shutdown.
The settle-out pressure(s) of each stage or stages shall be estimated during Basic Design and
confirmed after supplier selection. Design doccuments shall be revised to be consistent with the
confimed settle-out pressure from manufacturer.
Automatic depressurization system shall be provided, to be actuated during machine malfunctions,
according to supplier requirements and when fire and gas emergency signals occur.
The shared heat recovery configuration shall be avoided. Each turbo machine shall have its own
recovery unit, in order to allow proper maintenance.
The number of WHRUs shall be defined during Basic Design phase, based on process plant heat
demand analysis. It is not necessarily required to have a WRHU for the standby turbo machine.
The cooilng water system of each gas cooler of all Compression Units shall be protected against
overpressure as follows:
a PSHH shall be provided in the water system downstream heat exchanger (gas cooler) to
close water TV, to close gas inlet and outlet compressors SDVs and shutting-down the
compressor; water TV shall be FC type;
PSVs shall be provided in the water system.
The manual block valves of the water circuit (inlet and outlet) of each cooler shal be Fully
Tight Valve (FTV) type.
In addition, a gas detection system shall be provided in the vent of the water expansion vessel /
tank.
9.4. Depressurization
The compression stages shall be provided with a vent with a double block (needle+ball or
globe+ball) and blind flange for final depressurization of the machine (release for maintenance)
routed to a safe location.
The time-delaying BDV device appliance shall be assessed during design phases.
A restriction orifice shall be installed downstream the BDV for better adjustment of the relief flow.
In case of high CO2 content gas, solids formation shall be assessed in order to guarantee that no
obstruction will occur downstream of the reliefing/depressuring devices.
In order to avoid brittle fracture, minimum temperatures achieved during an isenthalpic depressuring
should be considered for material selection of letdown pressure devices (PSVs, BDVs, ROs) and for
the entire low pressure system. Piping sections upstream the letdown pressure device may also be
subjected to low temperatures and should be designed for co-incident high pressure at minimum
temperature.
If the condensate is to be stored in cargo tanks, it shall be commingled with oil upstream low
pressure stages, ir order to provide a single product with correct RVP. In this case, the dehydration
is not required. The most adequate treatment of the condensate shall be defined in Design Basis.
Basic Design shall consider, as a general rule for condensate destination, sending the liquid from
each process vessel to the vessel whose operating pressure is lower and closer to the source.
The following philosophy shall be adopted for condensate recovery from process vessels:
the liquid eventually collected in absorbing tower K.O. drum (Dehydration Unit) shall be routed to a
proper stage separator, according to operating conditions;
the liquid from the hydrocarbon dew point control unit vessels shall be routed to the proper oil
plant vessel, according to operating conditions;
the liquid from Safety K.O.Drum shall be routed to the proper oil plant vessel, according to
operating conditions;
the condensate from each compressor stage discharge scrubber shall be routed to the
previous stage inlet scrubber;
condensate from scrubber at the suction of Vapor Recovery Units shall be routed to flare
system K.O. drum.
10.1. General
For design purposes, a range of inlet contaminants shall be considered, as well as required
minimum and maximum capacity. The Design Cases shall be clearly presented on Design Basis.
The natural gas dew point specification shall comply with the following purposes (where applicable):
remove the higher hydrocarbon fractions from gas stream to be exported, in order to minimize
condensate formation inside the pipeline network and maximize gas transportation capacity;
limit the C6+ content at CO2 membrane removal unit inlet stream, as required by the
manufacturer. As a first approach the membrane feed gas C6+ content shall be in the range of
600 to 1000 ppmv.
The process shall be based on a Joule-Thompson expansion process. The process scheme shall
cover all possible process plant operating conditions, including start-up.
The Dehydration Unit shall be designed for the plants maximum gas handling capacity, not
including the standby compressor flow rate.
A choice shall be made between the triethylene glycol (TEG) and the molecular sieves technologies.
When TEG is used, H2O specification shall be stated on Design Basis. Molecular sieves are
typically used when stricter water content specification is required, such as 1 ppmv.
To determine the required specification for the dehydrated gas, all operational conditions envelope
of each gas stream end use (injection, exportation, lift gas or fuel gas) shall be assessed, including
low temperatures that might occur in process system and pipeline segments downstream the
offshore plant.
Special attention should be given to high CO2 content streams, due to the fact that CO2 tends to
increase water holding capacity at higher pressures.
For that reason, depending on CO2 content in the stream, it is not safe to set a water dew point
specification based on higher pressure requirements only, since water condensation may occur at
lower pressures.
A KO drum shall be provided upstream the absorption tower (integrated or as close as possible to
the tower).
The number of absorbing towers shall be defined during Basic Design phase. Preferably one
absorbing tower shall be used, if an adequate turndown can be accomplished for the minimum and
maximum production flowrate.
The Design Basis shall provide operating pressure and flowrate ranges to allow the definition of the
number of absorbers.
In order to determine the minimum design metal temperature (MDMT) for mechanical design and
material specification, only depressurization by the Emergency Shutdown (ESD) system of the SPU,
via BDV, shall be considered.
A single regeneration unit shall be used, regardless of the number of absorbing towers.
As part of the regeneration system, a vessel (flash drum) for glycol expansion and separation of the
hydrocarbons that might have been absorbed by the solution shall be provided. This vessel shall
have a residence time adequate for hydrocarbon separation, and vortex breakers shall be provided
at the liquid outlets, as well as a mist removing device at the gas outlet. The rich TEG stream shall
be previously heated in the condenser of the regenerator and then exchanging heat with lean glycol,
in order to help the hydrocarbon flashing. The bypass of this regenerator condenser shall be
provided with a temperature control system (TT, TIC and TV).
The TEG solution effluent from the expansion vessel shall be automatically controlled and go
through a cartridge filter, then through an activated coal filter for removal of degradation products,
followed by another cartridge filter for solids removal, and finally routed to the process for
regeneration of the solution.
An injection of treated stripping gas in the glycol reboiler shall be evaluated, by means of a
distributor in the reboiler or by a stripping column (Stahl column). Measurement of stripping gas
flowrate shall be provided.
The glycol reboiler shall be electric heater type, with an electronic temperature controller; provide
heating in stages and heat dissipation in an explosion-proof box. A jacket system shall be used,
provided with spare electrical resistances, allowing the resistors to be changed without draining the
glycol system. Energy demand calculations shall consider the thermal conductivity loss caused by
this jacket.
The unit shall be provided with a vessel to receive system drainage, storage and for glycol make-up.
This vessel shall have proper storage capacity (it should be capable of receiving the largest
inventory equipment draining, as a minimum). Glycol supply shall be made by gravity and a level
transmitter (LT) shall be provided, interconnected to the supervision system.
TEG piping from the reboiler outlet to the pump suction shall be designed considering cold TEG,
due to increased viscosity and higher pressure drop.
An SDV shall be installed between pump discharge and absorber tower in order to avoid gas
back flow in shutdown events.
The TEG/water cooler may be shell-and-tube or welded plate type, and located downstream the
glycol pump, with temperature indications for the four streams. Glycol/glycol exchangers shall be
plate type.
Inlet absorber tower gas temperature shall be as lowest as possible, limited by cooling system
temperature approach. Absorber tower inlet glycol temperature shall be 5 to 10C higher than inlet
gast temperature, to avoid hydrocarbon condensation and foaming. Monitoring and control of the
inlet temperature difference of gas and glycol shall be provided.
The regenerator vent line shall not have low sections (no pockets), in order to avoid back pressure
in the tower vent. The vent line shall be directed to a safe and independent area, not shared with
other vents and provided with flame arrester. A TEG vent trap to allow liquid collection or removal
and sample collection, shall be provided, as far as possible from the TEG tower.
The glycol pumps shall be positive displacement type. The pumps shall be independent per
absorbing tower, with a common standby.
A positive displacement type meter (oval gear) shall be used for measuring the circulating TEG flow.
The following variables shall be available in the supervision system: circulating glycol flow, stripping
gas flow, absorbing tower gas inlet and outlet temperatures, internal temperature for the absorbing
tower, absorber inlet glycol temperature, reboiler temperature, top of the regenerator tower
temperature, regenerator tower pressure, flash vessel pressure and temperature and all vessels
level.
A chemical injection control system for pH adjustment shall be provided, preferrably using MEA,
MDEA or other neutralizing amine.
Proper online monitoring of the moisture content or dew point of the treated gas shall be provided.
The analyzer shall display the direct information, avoiding internal conversion calculations that might
be inaccurate, especially in high CO2 streams.
For TEG units the selected point shall be located on an ascending vertical line and as distant as
possible from the gas outlet of the absorbing tower, such as at the inlet of fuel gas system, gas
export or gas lift header, and also distant from any interference like chemicals injection.
For TEG units, moisture meters with aluminum oxide technology shall not be used. Quartz crystal
microbalance or Tunable diode laser absorption spectroscopy technologies are acceptable.
For Molecular Sieves units, moisture meters with aluminum oxide technology shall not be used.
Quartz crystal microbalance technology is acceptable.
When specifying moisture analyzers, close attention shall be paid to the rangeability of each
instrument.
Sampling points close to each online analyzer shall be provided, to allow gas sampling to perform
the primary standard analysis according to ASTM D1142/95 (chilled mirror) for water dew point
determination.
In Molecular Sieves Units two different types are required: inlet high water content and outlet low
water content.
Proper sample conditioning shall be provided to each process.
All the requirements of this item shall be in accordance with DR-ENGP-I-1.6.
In order to verify the H2S scavenger efficiency, the H2S content shall be monitored by means of an
online H2S analyzer at the test separator, and at the inlet and outlet of the H2S removal unit.
The condensate dehydration unit shall be designed to achieve the required water content
specification at the maximum condensate flowrate. The unit shall comprise two systems, one for
free water removal using coalescer filters, and one for dissolved water removal using stripping with
dehydrated gas. Emulsion water may be removed in either one of these systems.
Additional technologies, such as molecular sieves and activated alumina adsorption, may be
evaluated for dissolved water removal.
The water content specification on dry condensate stream or gas and condensate stream, if
exported commingled, shall be stated on Design Basis, based on the most extreme flow conditions,
determined after the whole operation conditions envelope assessment (range of pressures and
temperatures).
Coalescer filter performance is affected by the presence of solid particles. Basic Design shall
include a pre-filtering system, upstream the coalescer, in order to remove them from the
condensate stream, thus protecting the coalescer filter and stripping column internals.
The coalescer filter shall be able to specify the condensate stream free water content to a maximum
of 15 ppmv. Furthermore, liquid holdup on the coalescer filter shall be considered in order to provide
steady condensate flowrate to stripping column.
Operation temperature shall be higher than cloud point (TIAC).
The Design Basis shall provide flowrate range to allow the definition of number of columns.
Preferably one stripping tower shall be used.
The remaining free-water, emulsion water and soluble water, this last one according to specification,
shall be removed from the condensate stream by dehydrated gas from the platform in counter-flow
through the stripping column. The wet gas stream from Stripping Column shall be dehydrated by
increasing its pressure to dehydrate it jointly with main gas stream.
Stripping temperature shall be based on simulation in order to ensure final condensate specification
and minimize stripping gas consumption and light hydrocarbons vaporization.
Flowrate ratio control between condensate and stripping gas streams shall be provided, with flow
indication of both streams.
At least the following variables shall be available in the supervision system: condensate inlet and
outlet temperatures and stripping column pressure, condensate flowrate, stripping gas temperature,
flowrate and pressure.
If continuous injection of hydrate inhibitor (MEG solution) is chosen to prevent hydrate formation in
gas/condensate wells, a MEG Treatment Unit (regeneration and reclaming) shall be required on
Design Basis.
The rich MEG storage capacity shall be at least equal to the lean MEG storage capacitiy plus the
maximum amount of produced water, according to reservoir simulations.
Rich and lean MEG tanks shall be internally split into two tanks, to allow proper cleaning.
The required lean MEG solution concentration shall be defined based on flow assurance studies.
The following guidelines shall be considered for the plant section upstream the MEG Treatment
Unit:
According to item 3.1.3 Number of stages and operation pressures/temperatures selection,
SPU incoming fluid heating is usually necessary. In order to optimize hydrocarbon separation
from rich MEG, upstream MEG unit, the liquid phase from the High Pressure Separator shall
be heated to a minimum temperature of 40 C. The minimum residence time and ideal
temperature values shall be determined by laboratory tests of emulsion formation;
The rich MEG coming from high pressure separation shall be flashed to a low pressure
separation stage to allow gas release;
As it is possible to have solids coming from wells, solids filters (such as bag and cartridge
filters) shall be provided to rich MEG stream;
As the condensate forms a stable emulsion with rich MEG, hydrocarbon filters (such as of the
coalescer and charcoal types) shall be provided to rich MEG stream;
The final polishing of the entire rich MEG stream shall be performed with charcoal filter,
followed by another filter for removal of charcoal particles;
The filtration system shall be located at the low pressure section of the Unit; the capacity of
the lean MEG storage tank shall be able to allow continuous lean MEG injection during at least
one day of operation, in case of MEG regeneration unit shutdown;
The following guidelines shall be considered for the MEG Regeneration Unit:
A salt removal section shall be part of MEG Regeneration Unit;
A centrifuge shall be provided as part of the salt removal section;
If the formation water is expected to have a significant amount of calcium ions, mainly as
calcium chloride, a proper system for calcium removal shall be provided upstream the vacuum
reclaiming section;
Slip stream operation mode (bypass of reclaiming section) is allowed, but the piping and
equipment of reclaiming section shall be designed considering the maximum flow rate
capacities, i.e, the full stream operation mode;
A chemical injection system for pH control shall be provided, using MEA, MDEA or other
neutralizing amine, to allow control of the pH of the MEG stream in order to avoid corrosion;
An oxygen scavenger chemical injection system shall be provided upstream the equipment
that operate under vacuum. The scavenger should be preferably a catalysed solution of
sodium bisulphite (maximum oxygen content in the rich MEG solution shall be 20 ppbv);
An oxygen monitoring system shall be provided for equipment operating under vacuum. This
system should comprise a sampling point to allow laboratory analysis and an online oxygen
analyzer or a portable device;
Nitrogen or other inert gas blanketing system shall be provided in all vessels, tanks and
equipment where the operation pressure is close to atmospheric, inside and upstream MEG
Regeneration Unit;
The lean MEG solution maximum salt content shall be defined on the Design Basis based on
measurements during Extended Well Tests or Formation Tests;
The aqueous effluent leaving the MEG Unit, if any, should be discharged overboard, and shall
have a maximum MEG concentration of 500 mg/L and comply with the Regulation CONAMA-
393;
In order to comply with the maximum oil in water content allowable as defined in
CONAMA 393, an additional filtration system shall be assessed;
In order to remove any particulate or corrosion products from the lean MEG solution, an
additional final filtration system shall be assessed;
The produced salt cake/brine may be discharged overboard as long as it fulfills the same
requirements for disposed water;
All equipment that may need frequent cleaning shall be provided with a spare one. The piping
of the unit shall have flanged spools and tie-ins connections and facilities for easy cleaning
operation;
Flow measurement instruments shall be installed in:
rich MEG stream inlet MEG unit;
recycle streams and the produced water stream;
lean MEG stream;
bypass stream from reclaiming section, when applicable.
CO2 and/or H2S removal unit need shall be defined on Design Basis. For produced gas containing
H2S, material specification shall comply with ISO 15156.
When there are no other guidelines, the desulfurization unit shall be designed for a gas specification
with maximum content of 5 ppmv of H2S.
The following guidelines shall be considered for selection of the CO2 and H2S Removal Units
technology:
For produced gas with CO2 content less or equal to 10%, amine technology shall be used to
remove both contaminants or to remove only H2S using selective amines;
For produced gas with CO2 content higher than 10%, membrane technology shall be used for
CO2 removal, and the permeated gas with enriched CO2 content shall be reinjected. In this
case, the following possibilities shall be assessed for H2S removal:
produced gas with H2S content less than or equal to 30 ppmv: the same membrane
unit shall be preferably used to remove this contaminant together with CO2. A proper
destination for the permeate gas with enriched H2S content (limited to 200 ppmv)
shall be specified, such as well injection;
produced gas with H2S content in the range of 30 ppmv to 170 ppmv: solid bed H2S
removal technology shall be used;
produced gas with H2S content higher than 170 ppmv: amine technology shall be
used to remove H2S only;
For low H2S contents, the subsea injection of liquid H2S scavengers may also be economically
feasible and, if selected, shall be required on Design Basis.
Technologies beyond guidelines mentioned in this doccument may also be evaluated for specific
scenarios.
For systems using membrane, a bypass with a block valve plus a flow control valve shall be used, in
order to allow partial and full bypass of the system.
draining the amine system. Energy demand calculation shall consider the loss of thermal
conductivity caused by this jacket;
A dedicated vent for the gas stream from the amine regeneration system shall be provided;
The performance of the treatment shall be monitored by a CO2 and/or H2S online analyzer at
the contact tower outlet, as a minimum, besides sample points to allow lab analysis;
The gas stream with high concentration of H2S coming from the regeneration unit shall be
preferably flared;
In case of Unit malfunction, the offspec treated gas shall be deviated to flare, through the
scrubber pressure control valve;
The low pressure gas shall be compressed to a pressure high enough to allow it to be routed to the
main gas compression system, commingled with first stage separation gas. Vapor Recovery Units
(VRUs) suction pressure shall be higher than atmospheric pressure.
VRUs package shall not include aftercoolers, since its discharge gas will be blended with the gas
from separators upstream of the main gas cooler.
The pressure control valve that routes the gas to low pressure flare shall be installed downstream
the scrubber vessel at the suction of the compressors. In case of vapor recovery compressor
shutdown, the gas shall be routed to low pressure flare system.
The vapor recovery compressors shall comply with item 4.2.3.2 of the DR-ENGP-II-P1-2.1
Mechanical Equipment Requirements.
The fuel gas at the turbine inlet shall be 20 oC above its dew point (minimum deltaT).
Pipes shall be insulated to keep gas temperature according to the specification.
A coalescer filter shall be used upstream the turbines and furnaces.
Part of the conditioned gas shall also be used for low pressure consumption of the Unit (such as:
flare pilot, deaeration, flare purge and gas blanketing).
Suitable means shall be provided for feeding and conditioning fuel gas from alternative sources
(test separator, gas pipeline, etc.) at plant initial start-up and also at start-up after a shutdown. The
specifications of the fuel gas shall be assured (dew point, temperature etc.).
The fuel gas system shall be so designed considering the periods to switch from fuel gas to diesel,
TG (gas buffer).
Gas heating shall be provided, when using alternative high pressure sources, in order to avoid very
low temperatures after gas expansion.
Metering shall be provided for high and low pressure fuel gas separately, overall and for the main
consumers (turbines, motors, deaerator, purge/assistance gas and flare pilot).
The disposal system analysis shall consider the following characteristics of the disposed flow and
fluids:
Flammable or non-flammable: only flammable hydrocarbons are considered here;
Toxic (H2S) or non-toxic: presence of H2S (>7 ppmv) shall make the gas to be analyzed as
toxic. Other toxic contaminants shall have special treatment;
High or low Pressure: the approximate value of 5 psig upstream of the orifices for outlet of the
vent or flare is considered as the division between high and low pressure systems;
Continuous or Emergency Duration: flows that last more than 15 minutes are considered as
continuous duration and those that last less than 15 minutes are considered as emergency;
Operational or Eventual Frequency: Operational are disposals that occur due the normal and
routine operation of the installations. Non routine or abnormal situations are eventual
occurrences;
Large or Small flowrates: flows over 100,000 Nm3/day are considered as large.
The atmospheric disposal systems of hydrocarbons are classified as following in decreasing order
of system complexity:
1-Multipoint flare (sub-sonic or sonic);
2-Single point flare;
3-High Velocity Vent (HVV);
4-Assisted Vent / Low-Velocity Vent;
5-Vent;
Tables 1 and 2 define the required minimum disposal system type based on the above described
flow/fluid characteristics. When defining the minimum disposal system, this means that may be
used any system type equal or superior in the decreasing classification above presented.
Table 1 Disposal of Flammable and Non Toxic Hydrocarbons
Pressure Duration Frequency Flow Minimum flow
high continuous operational large Multipoint flare (1)
low continuous operational large Multipoint flare
high emergency operational large Multipoint flare (1)
low emergency operational large Multipoint flare
high continuous eventual large Multipoint flare (2)
low continuous eventual large Single point flare
high emergency eventual large High Velocity Vent (3)
low emergency eventual large Single point flare
high continuous operational small High Velocity Vent
low continuous operational small Low Velocity Vent
high emergency operational small High Velocity Vent
low emergency operational small Low Velocity Vent
high continuous eventual small High Velocity Vent
low continuous eventual small Low Velocity Vent
high emergency eventual small Vent
low emergency eventual small Vent
Notes of Table 1:
(1) this flare shall be as much as possible with stages so that the flow released to the environment with
velocity under 150 m/s is under 3% of the maximum flow (capacity) of the system;
(2) High Velocity Vent (VAV) carefully designed may be accepted;
(3) Multipoint flare may be a recommended option;
The flare system shall execute the combustion of the gaseous effluents disposed by the SPU. The
combustion shall be maintained stable with winds up to 100 km/h even at low gas outlet velocity.
The flare system shall appropriately burn any gas flow from minimum to maximum flowrate, at any
burning condition, continuous and emergency. The materials of the flare system and support
structures shall be specified for withstanding emergency gas flow for a minimum of 24 hours and
continuous gas flow for non determined time.
As a minimum, the following SPU situations shall be considered as possible causes for emergency
burning conditions:
depressurizing;
fault and loss of instrument air;
fire in some selected areas;
maneuver error;
shutdown of the compression system.
For projects using normal-stop depressurization compressors, the flare shall have capacity for
burning the gas flow from the compressor depressurizing, added to the arriving flow at the same
compressor inlet. This burning condition shall be classified as emergency.
The flare type selection shall consider the following items:
issued thermal radiation;
required burning quality;
maximum flame length;
available pressure;
maximum flowrate turn-down;
jet thrust force;
composition of the flaring gas;
admissible noise level;
maintenance facilities;
arrangement characteristics;
supporting structure;
campaign duration between stops and
flare replacement system (helicopter, crane or traditional).
Additionally, depressurizing lines to the flare shall be provided for the depressurizing of the gas
pipelines (with manual control) and the annulus of the lift-gas boosted oil-wells. These
depressurizing operations may be performed only after the plant depressurizing. The supporting
structure length and other flare system dimensions shall not be sized on these depressurizing
conditions.
The high pressure flare system shall assure complete burning (minimum efficiency for destruction of
hydrocarbons of 99% and conversion to CO2 of 98%) smokeless standard Ringlemann 0, between
the minimum and maximum operation flow.
When the design leads to a flare support structure over 100m, water injection on the flame shall be
provided with the purpose of emitted radiation reduction. The water injection shall be done at the
center of the gas orifices of the burners. Sea water may be used, but the lines shall be flushed with
fresh water immediately after being used. The water line material shall be appropriate to avoid
service corrosion. Structures and flare components shall be manufactured in high-temperature and
salty-mist corrosion resistant materials.
The low pressure flare system shall assure complete burning (minimum hydrocarbon destruction
efficiency of 99% and minimum hydrocarbon conversion to CO2 of 98%) smokeless standard
Ringlemann 0, between the minimum and maximum operational flow.
In order to achieve the required burning efficiency and also the required smokeless combustion,
assisting gas shall be used. The assisting gas shall be of good burning quality (fuel gas).
The sizing of the supporting structure geometry shall be conducted considering the emergency
burning conditions. Thus, the continuous burning capacity shall be limited to the feasible maximum,
considering the above sizing, as long as:
a) Interlocking shall be implemented for closing the wells or limiting the production, in case of any
possible flaring flow larger than the flare continuous burning capability (e.g. shutdown of
compressors);
b) during the Basic Project the flow contribution to the flare due to the transient between
compressor stop, PV opening and well closing shall be studied and a complete report shall be
issued.
The flare supporting structure geometry shall be defined in the Basic project, but shall preferably be
of tower type.
The flare thermal design shall comply with the API-STD-521/ISO 23251, mainly in the admissible
maximum total radiation fluxes over the working areas. Under continuous burning conditions, the
maximum total flux of thermal radiation incident on the platform working areas may not be larger
than 1577 W/m2, with 789 W/m2 due to the flare and 789 W/m2 due to the sun. Under emergency
burning conditions, the maximum thermal total radiation flux incident on the platform working areas
shall not be over 4737 W/m2, for a period of 3 minutes, as recommended by API-STD-521/ISO
23251.
The maximum total radiation fluxes incident on the working areas shall be calculated adding the
corresponding maximum radiation fluxes produced by continuous and by emergency conditions of
high and low pressure.
The flare-system thermal design shall assure the compliance with these guidelines of the maximum
total radiation fluxes incident on the working areas, without the need of any heat-shield in the
platform.
The flare supporting structure heat-shield shall be minimized and analyzed for each project. The
flare thermal design shall analyze the extension and composition of the boom structure thermal
protection heat-shield. The flare steel structure temperature shall not be over 310C in any situation.
The flare system shall have two scrubbing vessels, one for the high pressure flare system and one
for the low pressure flare system.
The scrubber vessels shall be sized with capacity for liquid hold-up, between the normal liquid level
and the maximum level causing stop level 2 (ESD2), selected with the larger estimate values from
the following cases:
Larger value obtained by simulation;
Liquid flow corresponding to 5% of the mass gas flow for all burning conditions;
Total liquid flow of the SPU during 90 seconds;
Maximum liquid flow of the well with larger flow during 10 minutes;
The design shall consider that the space reserved for the gas shall be appropriate for retention of
droplets larger than 300 micra, even during the occurrence of maximum liquid level.
A facility shall be provided for gravity drain of the flare vessel, by LV on-off within a maximum time
of 5 minutes. The diameter of the drain line shall be minimum 3 inches, considering that the liquid
consists basically of condensate and oil at the lowest possible depressurizing temperature. The
pump shall have capacity for draining the vessel in 5 minutes. The selection of the pump shall be
according to the characteristics of the liquid to be pumped at operation temperatures.
Provide heating of the flare vessels at the liquid region, in order to avoid freezing the collected
liquid.
The lines of the relief and depressurizing network of the plant shall not present low points in order to
avoid accumulation of oil/liquid and shall have a minimum slope of 1% in the direction of the flare
vessel. In case this is not possible to avoid, drain points shall be provided, with automatic drain to
the recycle vessel of the plant. These drain points shall not allow air inlet into the lines of the relief
and depressurizing system.
The lines of the relief and depressurizing network that direct the gas from the flare vessel to the
flare shall have a minimum slope of 1% in the direction of the flare vessel. If not possible, drain
points shall be provided and applied the same design rules of the piping of the relief and
depressurizing system of the previous paragraph.
The design of the lines for the relief and depressurizing network in floating vessels shall consider
the slope (reduction of ship FPSO) and movements of the vessel (roll, pitch, heave, trim and heel),
for assuring the return of the liquid to the flare vessel.
The network of the high pressure flare system may be divided into two collectors to the flare vessel,
with one collector for low temperatures and another one for higher temperatures. Thus, only the low
temperature collector would need special material.
The flare pilots shall be fed with natural gas from the fuel gas system and, as back-up, from GLP
bottles with manual drive. For installations with low pressure gas pipeline, provide an additional
connection, with scrubbing system, from this gas pipeline to the pilots.
The pilots shall be designed for maintaining stable burning with wind up to 160 km/h and rain.
The pilot flame shall be permanently monitored by thermocouple with local sound alarm and in the
control room. This system shall have back-up based upon one of the following technologies: UV
radiation, IR radiation, flame ionization or acoustic signature of the flame.
The pilots shall be turned on by a flame front system and by a electric-electronic system. Automatic
relighting shall be by an electric-electronic system with local action or from the control room.
13.2.9 Purge
Purge gas shall be injected in the gas piping system to the flare at the point(s) more distant
upstream, i.e., more distance from the flare so that all the piping shall be full of purge gas and under
positive pressure.
For stage systems, provide a point for nitrogen purge downstream from each valve of the stages
normally closed, in order to maintain a continuous flow of purge gas up to the top of the flare.
The purge gas flow shall assure a minimum speed of 0.15 m/sec, in the orifices for gas outlet to the
environment. In the piping with larger diameter, may be adopted lower purge gas flows, as long as
complying with the requirements of API STD 521.
At least two sources of purge gas shall be provided, with provision for measuring flow, low flow
alarm and automatic changing between sources. The first source shall be gas of good quality (fuel
gas), and the second one shall be a large volume source. Purge gas to Flare shall be monitored by
3 (three) low flow transmitters arranged in a two out of three logic for starting ESD-2.
The purge gas shall be natural gas, using nitrogen as back-up, locally produced from atmospheric
air, and by a specific unit dedicated to this function fed as essential charge. The generated nitrogen
shall have purity over 96%.
In case of using low velocity flare (single point), shall be provided with molecular or fluid seal, for
reducing the consumption of purge gas.
The HP flare header shall operate in a pressure range defined by the following:
(i) the intermediate pressure level sets the relieving of its gas flow rate to the LP flare header by
opening a communication line between both flare headers,
(ii) the high pressure level sets the opening of the HP QOV to the HP Flare,
(iii) the low pressure level sets the closing of the communication line between the HP and LP flare
headers.
The LP flare header shall operate in a pressure range defined by the following:
(i) the intermediate pressure level sets the starting of the pressure recovering equipment
(compressor, eductor, blower, etc.) which recovers the LP gas from the LP flare header to the inlet
of the main gas compression system,
(ii) the high pressure level sets the opening of the LP QOV to the LP Flare and the closing of the
communication line between LP and HP flare headers,
(iii) the low pressure level sets the stopping of the pressure recovering equipment.
All these six pressure levels shall be wisely selected for and safe running of the Closed Flare
system.
The HP and LP flare headers shall be purged with low purity nitrogen (96 to 98%) locally generated
from the atmospheric air by small dedicated generators. The N2 generators shall have 2 x 100%
arrangement and shall be fed by the emergency electric circuit. If the two nitrogen generators fail, a
dedicated natural gas line shall supply purge gas for the system. The purge system shall have flow
rate measurement with low flowrate alarm and automatic switch of purge gas supplying source. The
purge gas shall be injected in the HP and LP flare headers closely downstream to their QOV valves.
Oxygen sensors shall be installed in the HP and LP flare headers downstream their QOV valves.
The oxygen level inside the flare headers shall be maintained below 5% in volume.
The flaring gas sent to the flare shall be ignited as soon as it reaches the flare burners. Two
concomitant pilot systems shall be installed: (i) continuous electric sparking system and (ii) sparking
pellets. The first one has several sparking devices at the flare tip (burners). The sparking device can
either run continuously or be started only when the QOV valve opens. However, enough reliability
shall be demonstrated on the starting of the non-continuous option and enough endurance shall be
demonstrated by the continuous one. The second one is based on the pellets or small rockets
propelled by compressed air. The pellet is sent in high velocity through a small diameter pipe from
the platform to the flare tip where it hits a steel plate close to the flare burners. A large cloud of
sparks ignites the flaring gas. A certain delay will have to exist between the QOV opening (flaring
gas delivery) and the pellet dispatch because a gas-air mixture cloud has to exist near the flare tip
when the pellet hits the steel plate.
The ignition system readiness and availability have to be continuously monitored and corrective
measures shall be immediately taken even when the flare is not being used.
Equivalent solutions for closed flare systems may be considered. However, the closed flare system
shall fulfill at least the features described here.
The design of the Atmospheric vent system shall be according to API RP 2000.
The lines of the atmospheric vent system shall have a route that does not allow liquid accumulation.
The maximum head loss of the vent system shall not exceed the maximum allowable pressure of
the vessels and tanks interconnected to the vent system.
The material of the lines shall be compatible with the characteristics (temperature, composition,
etc.) of the exhaustion gases of the system.
A study shall be conducted for the dispersion of gases for the low velocity vents. However, this
study is not necessary for the high velocity vents, except for the flows of the first stage at outlet
velocities under 150 m/s.
The first stage shall not be sized for maximum flow over 10% of the total flow of the vent system.
The first stage shall be provided with flame arrester on line appropriate for gas of explosion group
IIA (BS EN 12874:2001) with measurement of differential pressure, monitoring for flame presence
(thermocouple) with automatic drive of the arrester system with CO2. The flame arrester shall have
internals (mesh screen or equivalent) manufactured in stainless steel 316 or better.
The system shall have two identical first stages and blocked by mechanically interlocked valves, to
allow maintenance and plugging test (connection for injection of N2 or other gas) of the flame
arrester of the first stage that is out of operation without removing all the VAV system from the
operation, which would led to the shutdown of the SPU.
The VAV system shall be protected by safety outlets with the same capacity of the VAV system,
protected by buckling pin valves. These safety outlets may be arranged as follows: (i) one buckling
pin valve per on-off valve for command of each stage, (ii) two stages of safety with buckling pin
3
valves each one with 50% of the capacity of the VAV (VAV larger than 1,000,000 Nm /day) or
(iii) just one safety stage with buckling pin valve with 100% of the capacity of the VAV (VAV smaller
3
than 1,000,000 Nm /day).
The buckling pin valves shall have the opening pressures scaled for avoiding the simultaneous
opening of all the valves at the same time. It is recommended that the opening pressure of the
buckling pin valves should be 50% over the larger operation pressure of the on-off valves of the
stages. Notice that the pressure for mechanical design of the scrubber vessel of the vent shall be
larger than the sum of (i) maximum head loss between the scrubber vessel of the vent and the VAV
and (ii) pressure for opening the buckling pin valves of the VAV.
The distance between the flame arrester and the orifice for gas outlet shall not be larger than the
distance for which the flame arrester was tested and certified. Do not use flame arrester of line end
type and with cover.
The final location of the outlet orifices of the first stage shall assure that the flow of the first stage
when at 150 m/s shall be duly dispersed and not promoting radiation, in case of ignition, larger than
2650 W/m2 over the work areas.
The on-off valves for command of the stages shall be of closed fail type. Facilities shall be provided
for tightness tests of the on-off valves for command of the stages: one connection for injection of N2
between the block valves of the stages and the on-off valves allowing the installation of a
manometer for checking the eventual head loss indicating a leakage. Periodic tests shall be
executed for the operation of the VAV system.
The need for purge gas for the high velocity vent system shall be defined by the Basic project.
The low velocity or low pressure vent system shall comply with the collection of gas of the
equipment that operates at atmospheric pressure or near atmospheric and which gas inventory may
be safety dispersed in the atmosphere.
The discharge of this system may be directed to a safe location in accordance with the study for gas
dispersion, may be at a point along the flare support structure, so that the exhaustion gas is not
ignited by the flare flame and does not form a flammable or toxic mix in the SPU.
If the system pressure is lower than 0.15 psig, this may be provided with flame arrester for line end.
If the system pressure may be over 0.15 psig, this shall be provided with flame arrester in line
middle with internals manufactured in stainless steel 316 or better.
If the distance measured along the axis of the piping between the vent end and the flame arrester is
less than 50 diameters, the middle line flame arrester may be of deflagration type. If this distance is
over 50 diameters, the middle line flame arrester shall be of detonation type.
The middle line flame arrester of deflagration type shall always have a flame detector
(thermocouple) for detecting the presence of internal flame, next to the flame arrester element and
downstream from the same. The detected flame shall automatically trip (instantaneously) the flame
arrester system (CO2, N2, etc.), trip a local alarm and in the control room. The detonation flame
arrester, installed beyond 50 diameters from the vent end, does not require dampening system, nor
temperature sensor.
All the flame arresters with continuous operational flow shall be equipped with differential
pressostate (middle line flame arrester) or simple pressostate (upstream from the end line flame
arrester) with local indication and in the control room.
The distance between the flame arrester and the gas outlet orifice (vent end) may not be larger than
the distance for which the flame arrester has been tested and certified. All the flame arresters shall
be appropriate for gas of explosion group IIA (BS EN 12874:2001).
The vents should be individual, i.e., as much as possible or reasonable, each vent shall serve a
single equipment. The objective is to assure the higher outlet velocity of the gas in order to
maximize its dilution with air and avoid the pressurization of an equipment by the discharge of some
other equipment.
The vents of the recycle vessel of the plant, glycol regenerating tower (MEG/TEG), amine
regenerating tower, and all the other systems with continuous flow shall be independent, with the
objective of avoiding risks of incorrect pressurizing.
In case of units with turret, the vent of the tanks internal to the turret shall be installed at the highest
point of the turret.
13.3.3 Vents
The discharges shall be installed in high locations of the SPU in the direction of the predominant
winds.
The vents should be individual, i.e., as much as possible or reasonable, each vent shall serve a
single equipment. The objective is to assure the higher outlet velocity of the gas in order to
maximize its dilution with air and avoid the pressurization of an equipment by the discharge of some
other equipment.
In addition to the provisions of the DR-ENGP-I-1.3 Safety Philosophy, a shutdown valve (SDV)
shall be installed in the gas export line. In case of FPSO with turret, the SDV shall be installed
upstream and downstream of the swivel.
The compression capacity shall comply with the injection curve (flow and pressure) defined by the
reservoir studies.
The condensate eventually generated in compression, shall be moved in cascade to the scrubber
vessel with a immediately lower pressure level. See the description of the main compression
system.
Install check valves in the annular lines, between the interconnection of the injection system and the
block valve of the service line.
Each gas injection well and injection manifold shall be provided with monitoring for pressure and
flow measurement.
When required by the reservoir study, water injection shall be provided. This system shall be sized
so as to be suitable for injection curve plus 20%, without back up.
The water injection system shall provide monitoring of corrosion according to the Corrosion
Monitoring chapter (chapter 21).
Coarse Filters
For specification of the filter at the sea water connection, see DR-ENGP-II-P1-1.2 General Criteria
for Non-Electric Utility.
Upstream from the first equipment of the treatment system for injection water (SRU or deaerator),
candle type, 25 micra, self cleaning filters shall be installed, with spare filters, in order to allow
maintenance without reducing the injection. The back washing of these filters shall be conducted
with the filters under operation.
The metal filter element of this filter shall be the wedge wire type. The maximum filtering rate shall
be 8300 m3/h/m2 (AAFT total filter open area). The material of the casing and cover of the filters
shall be lined carbon steel and the internals shall be in stainless steel AISI 316L, AISI 321 or
superduplex.
Fine Filters
Water quality specification shall be defined in the Design Basis and shall comply with the provisions
of the latest revision of E&Ps Manual of Water Injection.
For water injection systems without SRU, the fine filter shall consist of cartridge filters with nominal
and depth filtration, with spare filters in order to allow the filter elements to be changed without
reducing the injection. The filter elements shall be of polypropylene, outer diameter 2.5 inches, inner
diameter 1 inch and 60 inches of length, without splices, with outside-in water flow. The filter rate
shall be 4.2 m3/h/m2. The material of the casing and the cover of the filters shall be lined carbon
steel and the internals shall be in stainless steel AISI 316L, AISI 321 or superduplex. The filters
shall be provided with quick closing/opening system.
For water injection systems with SRU all fine filters (injection and SRU CIP filters) shall be the
absolute type in order to assure the Silt Density Index (SDI) specified by the manufacturer of the
membrane. The filter elements shall be in polypropylene with a diameter of 6 inches, 60 inches
high, O-ring for sealing, inside-out filtering. The filter rate shall be 1.25 m3/h/m2. The material of the
casing and cover of the filters shall be lined carbon steel and the internals shall be in stainless steel
AISI 316L, AISI 321 or superduplex.
For FPUs which require diluition water system with reverse osmosis the fine filters shall be specified
with the same requirements of the SRU fine filters.
The closing system of the filters shall be of quick opening type.
A dedicated chemical injection system shall be supplied together with the SRU package.
A 2 stages SRU unit shall be considered. The first stage shall be divided in two banks. Shall be
considered the 5x20% train configuration.
Figure 9 presents a schematic configuration of a SRU single train.
Shall be foreseen spare nozzles installed for additional vessels corresponding to 10% of each bank
capacity, in order to guarantee operational adjustments to the units hydraulic balance and the
efficient control of pressure and flow.
Flow rate measurement shall be foreseen in permeate and discharge inlet and outlet of the first
stage. Flow rate measurement shall be foreseen in permeate and discharge outlet of the second
stage.
In permeate lines, PSV shall be used instead of rupture disk.
Biocide DBNPA system injection shall be of non-metallic material.
Redox analyzer shall be duplicated. with logic interlock 1 of 2 and anti-scale and chloride scavenger
dosages shall be interlocked with the SRU. In addition to the flow meters these instruments must
have a by-pass to allow maintenance.
Cleaning System
Storage tank for fresh water without chloride, dedicated only for SRU and turbine cleaning shall be
foreseen. This tank shall be design to be filled by the fresh water generator system and by the
supply ship. The tank capacity shall be designed considering 1 m for each 100m/d of SRU
permeate.
Shall be considered two tanks for cleaning operation. Each cleaning tank shall be designed for one
train and sized considering 0,125 m volume for each membrane. The cleaning system shall have
alignment flexibility for one train, stage or bank cleaning.
Shall be designed two cleaning pumps, 2 x 100% configuration, allowing any train cleaning with any
pump. Cleaning filters shall have 1 x 100% configuration and shall present the same requirements
of the fine filters for sea water injection system.
Cleaning flow rate measurement shall be installed in pump suction position.
Cleaning pump capacity shall be a maximum of 10 times the number of vessels o fone train (ex.:one
train with 60 vessels will have 600 m/h flow rate for each pump) with operational pressure range of
750 a 1000 kPa. The cleaning system shall have recirculation line positioned after the cleaning
pump returning to the tank with no communication with the discharge line.
Cleaning system shall be by means of valves and is not allowed to use manual connection swing
elbow type.
Cleaning system shall be designed only for liquid products with piping dedicated to cleaning tanks
feeding.
Membrane cleaning system fresh water line shall be with inert material
The top of the cleaning tank shall be in free area location with no cover.
SRU drainage system shall be directed to platform non-hazardous open drain.
Deaerator Tower
The physical deaeration system shall be designed for a maximum O2 content of at 50 ppb.
The chemical deaeration system shall be designed for a maximum O2 content of at 10 ppb.
The deaerator tower shall be internally lined with non metal material for corrosion resistance.
The deaerator type shall be defined by the Design Basis.
Pumping System
The pumping system shall be sized for the predicted injection curve plus 20%, without back up.
The minimum flow of these pumps shall be directed to the overboard system.
The reinjection of produced water has the objective of disposing this water in the reservoirs, aiming
for geological storage or secondary oil recovery.
The produced water reinjection system shall be installed downstream of the oily water treatment
system and shall include the following equipment, whenever applicable:
Filter system;
Pumping system;
This system shall be designed for compliance with the specification of water quality in the field,
provided by the Management of Asset Reservoirs of the field where the SPU shall be installed.
The installation of a corrosion monitoring system shall be provided according to the chapter of
Corrosion Monitoring (chapter 21).
Do not use cartridge filters with acid cleaning.
In case of filter systems with back washing (mixed bed or nut shell), an additional system shall be
provided for back washing water treatment, to be defined in the Basic Design.
This section describes the cases where a flow meter system shall be installed. If any of these points
are included in custody transfer metering, no duplicate points shall be allowed.
The metering systems shall be in accordance with DR-ENGP-I-1.6 Guidelines for Oil and Natural
Gas Measurement Systems.
Provide instantaneous flow metering and total metering at the following points:
Water injection import line;
Water injection export line;
Main header to the manifold,
Individual flowline;
Subsea injection manifold header.
Design Basis shall provide details about sampling points in accordance with the P&ID-General
Notes issued in the last project.
For each sampling point, the following items shall be included as notes in the P&ID:
Sampling valves shall be located and positioned in order to minimize segregation of fluid
components;
Preferably use points located in vertical sections, with ascending flow. Where this is
impracticable, select points with turbulent flow to ensure that the fluid components are suitably
mixed. Sampling points must not be placed in descending flow;
Avoid installing sampling points of hard access or situated on very high or low places in order
to guarantee readiness of access and minimize ergonomic issues;
Do not use pipe ends and zones without turbulent flow.
Provide sampling point collectors with sufficient drain line capacity and diameter, to avoid overflow.
Material for sampling point construction shall be compatible with the sampled fluid and with pipe
specification.
The possibility of precipitation of organic and inorganic compounds during the definition of the
sampling point type shall be evaluated.
Water inlet and outlet of the oily water treatment system equipment;
Slop and FPSO/FSO offloading line.
When using online meters, follow DR-ENGP-I-1.6 Guidelines for Oil and Natural Gas
Measurement. In this case, manual samplers shall be placed downstream of the meters, for
calibration.
Sampling valves shall be located on the upper part of the lines, when installed in horizontal sections.
Provide valves at the following points:
Gas outlet line of each production and test separator vessel;
Upstream from the compression system, downstream from the scrubber vessels;
Downstream from the scrubber for each compression stage;
Downstream from the gas dehydration unit, before the injection point (point for chemical
injection);
Fuel gas system, downstream from the scrubber vessel;
Gas import lines coming from other platforms;
Upstream of the vapor recovery compressor;
Upstream and downstream of the CO2 and/or H2S removal unit;
The valve construction material shall be the same as the water piping to the first block valve, and
316 L stainless steel thereafter.
Install the REDOX potential meter at the same sampling point (upstream of the deaerator). Install
the dissolved oxygen meter/transmitter downstream from the main injection pumps, near the
corrosion monitoring points. Install the particle counter analyzer downstream from the main injection
pumps.
In case of condensate being directly added to the oil, see item 17.2.1.1.
In case of a separate condensate treatment plant, provide valves at the following additional points:
Inlets and outlets of coalescer filter;
Inlets and outlets of stripping unit.
The samples collected at the MEG treatment plant must have its solid content separated and
analyzed separately.
Provide sampling valves at the following points:
Inlet of MEG Regeneration Plant (rich MEG);
Rich MEG outlet of low pressure separator upstream of the pumps;
Inlets and outlets of pumps and heat exchangers (cold and hot process streams);
Outlets of chemical injection pumps;
Inlets and outlets of all filters;
Top and bottom outlets of all distillation columns (such as: atmospheric, vacuum, etc.);
Appropriate sampling points according to chosen salt separation system (such as: brine
displacement, centrifuge etc.), in each of the constituent equipment (inlets and outlets, and
inside the equipment when applicable);
Brine overboard discharge line, after dilution with water;
Outlet of MEG Treatment Plant (lean MEG).
Install an automated chemical metering system on each injection point. The variable process signal
(on-line or not) feeds the PLC, generating a flow rate signal, in accordance with the required
injection rate (set point).
The injection system may use individual pumps or a multipoint metering system. Both systems shall
be provided with flow metering control (positive displacement type). Differential Pressure Control is
not acceptable. Flow control with control valve or cycling valves is acceptable.
Provide all injection points with both current flow rate and totalized volume displayed in the
Supervisory System.
Each injection point shall be in the center of pipe.
Provide an individual filter at the chemical pump suction.
When using dosing pumps, these shall be the piston or double-diaphragm type (protection against
leaking of toxic products). In case of systems that shall not be automated, use dedicated pumps for
each type of product and an injection point, with lock in the regulation system.
The applied injection system shall be provided with a graduated calibration column to determine the
flow rate at the suction, with shock protection.
Check valve and block valve shall be provided in the chemical injection lines, as near as possible to
the injection point.
Headers of positive displacement pumps shall be provided with a relief system (PSV).
At least one stand-by pump shall be provided for each chemical.
18.2. Inventory
The supplying calculations shall consider a chemical product inventory (tanks + drums) sufficient for
at least 7 days of normal consumption, calculated by using 80% of the maximum injection rate
indicated in the tables of this section.
18.3. Layout
The Unit lay-down area shall have free space for tanks or barrels for an additional 7 (seven) days of
consumption.
The layout shall include structures for tank filling, which shall be by gravity whenever possible, and
by means of a reusable container.
Install the hydraulic unit next to the chemical product unit, to avoid separate storage areas.
Locate the storage of flammable and toxic products in a process area, so that this storage shall not
affect the classification of the other areas.
Chemical tanks and their lines should be of fiberglass, whenever possible. Fiberglass shall not be
used in case of flammable products. Locate the tanks in naturally ventilated areas, and provide
them with individual air vents. The tanks for flammables shall also be provided with flame arresters
and CO2 discharge.
18.4. Tanks
Each tank shall be provided with an independent 2-inch feed line, with 10-mesh screen, to avoid
product contamination. Do not use supply manifolds.
Tanks for chemicals shall have the following characteristics:
Cone bottom to facilitate cleaning;
Coamings to contain liquid spills
Manhole to allow internal inspection and cleaning;
Liquid level gauge. Provide remote tank level monitoring for unmanned platforms;
Easy access to instruments and valves;
High level alarm;
Low level alarm;
Tank sampling valve (may be on the pump discharge).
The tables presented in items 19.1, 19.2, 19.3, and 19.4 show the injection rates of products ready
for use, not needing dilution. Exception is made in the case of inverted emulsion breaker
(polyelectrolyte) and gas corrosion inhibitor (injection in points other than gas exportation).
Consider the following values for designing the chemical injection system:
INJECTION RATE
PRODUCT TOXICITY CORROSIVENESS FLAMMABILITY
(ppm)
Antifoam 5 to 80 yes no yes
Antifoam Additive 5 to 80 yes no yes
15 to 100 (topside)
Demulsifier yes no yes
15 to 300 (subsea)
The Unit shall be prepared to inject oil defoamer continuously topside using individual metering
pumps, downstream of liquid sampling points. The injection points are:
Production and test headers;
Upstream of oil level control valve of the first stage separator.
If the oil production test requires using antifoam additive injection, provide facilities to inject antifoam
additive as close as possible to the antifoam injection point.
18.5.2 Demulsifier
Topside scale inhibitor shall be continuously injected at one of the following points in produced fluid
line and oil treatment:
Close to the DCT, downstream from the liquid sampling point;
Production and test headers, downstream from the liquid sampling point;
Upstream of treaters;
Other points according to scaling study.
Each well will have individual pump (or multi head pump) and line coming from the platform in order
to allow injection of scale inhibitor.
Scale inhibitor for subsea shall be injected continuously at one of the following points:
WCT;
Well down hole (in all production wells at the same time), for wells with tendency for scale
formation in the production line, providing facilities for downhole injection.
Scale inhibitor injection system should be capable to operate the full injection range per well.
Note: Wells equipped with ESP shall have demulsifier and/or scale inhibitor injection (if necessary)
upstream from the pump. Only compatible chemicals shall be injected at same point.
Provide facilities to inject demulsifier or scale inhibitor in the WCT using umbilical lines. Product
injected upstream from ESP is not required to be injected in the WCT.
Demulsifier and scale inhibitor injection points shall be located as far as possible from each other
(minimum 2 meters) due to the incompatibility between them.
18.5.6 Xylene
The use of xylene will be done through service boats and there is no need of xylene storage.
Injection rate will be informed during the engineering detailing phase.
Basic design shall include a corrosion study, to define the need for corrosion inhibitors. However, a
flanged valve shall be installed, upstream of the transfer pumps, for corrosion inhibitor injection.
To inhibit hydrate formation, ethanol shall be injected into the producing Wells Wet Christmas Trees
at 5,000 L/h. The injection is not planned to be continuous, however, it should be possible to inject it
in up to two points at the same time. It should be provided the required flow rate and pressure at the
top connection of each control umbilical at the SPU.
It should be provided an area next to 5,000 L/h pump for future installation of a low dosage pump (1
to 200 L/h) for injection of Low Dosage Hydrate Inhibitor (LDHI).
Minimum ethanol storage capacity: 20.0 m3 built-in tanks and the necessary storage area for the
extra 20.0 m3.
To design this Unit, it shall be considered that the hydrate formation temperature, will, at least, be
kept 5C below the stream temperature. A safety mar gin of 15% shall be considered.
If an H2S Scavenger is needed, facilities shall be provided to inject the scavenger into WCT or
downhole, using umbilical lines, or each gas lift line, if the production string material is not suitable
for H2S.
All injection points shall use spraying nozzles to distribute the chemicals.
Consider the following values for calculating the chemical system:
INJECTION RATE
PRODUCT TOXICITY CORROSIVENESS FLAMMABILITY
(ppm)
1 to 15 L/h per well at
Hydrate Inhibitor gas lift line; yes yes yes
300 L/h export line
Gas Corrosion
1L/106 scf gas yes Yes yes
Inhibitor
H2S Scavenger 25 L / Kg H2S yes Yes yes
Additional injection points are required at the topside facilities in case of gas dehydration treatment
malfunction. Those additional points shall be installed with spraying nozzle devices to accelerate the
mixing of inhibitor and gas. Retractile nozzles system is required for maintenance.
Provide the following injection points for hydrate inhibitor and/or corrosion inhibitor, as required:
Gas exportation pipeline;
Gas-lift system;
Downstream from the gas injection compressors;
Upstream from the fuel gas pressure control valve;
Condensate outlet of the high pressure fuel gas vessel.
Hydrate inhibitor shall be injected in the gas-lift line, individually per well, and independent of the
injection in the gas exportation line, using a spraying nozzle.
To design this unit, it shall be considered that the hydrate formation temperature, will, at least, be
kept 5C below the stream temperature. A safety mar gin of 15% shall be considered.
The minimum flow rate for each injection point shall be 1 (one) liter/h.
The unit shall be prepared to inject continuously, topsides, the corrosion inhibitor into the gas export
pipeline.
Provide the following points for injection of corrosion inhibitor, as required:
Upstream from the gas compression suction cooler, inter-stage, and discharge;
Gas exportation pipeline;
Downstream from the gas injection compressors;
Upstream from the fuel gas pressure control valve;
Condensate outlet of the high pressure fuel gas vessel.
Except for the gas pipeline, apply the corrosion inhibitor diluted in ethanol, 1:1 ratio, for the other
injection points.
Corrosion inhibitor tanks shall be of stainless steel.
INJECTION RATE
PRODUCT TOXICITY CORROSIVENESS FLAMMABILITY
(ppm)
5 to 20 (Normal op.)
Oxygen Scavenger
100 to 200 (no yes yes no
(Sodium bisulphite)
deaerator)
Scale Inhibitor 20 to 100 yes no no
Biodispersant 5 to 20 continuous yes no no
Shock Biocide 100 to 1000/ twice a
yes yes no
(THPS) week/1 hour
SRU Chloride
Scavenger (Sodium 1 to 30 yes yes no
bisulphite)
SRU Scale Inhibitor 1 to 20 yes no no
SRU Biocide 100 to 500 / twice a
yes yes no
(DBNPA) week/1 hour
Calcium or sodium
50 a 500 yes yes no
Nitrate
Acid Cleaning (SRU) Batch use yes yes no
Alkaline Cleaning Batch use yes yes no
SRU cleaning chemicals disposal shall be neutralized before being sent to the FPSO slop tanks
Oxygen and SRU Chlorine Scavenger shall be injected in the water injection system at the following
points:
Deaerator vessels;
Downstream of deaerator by-pass line;
Using the individual dosing system, only one of the points shall be used at the same time.
Biodispersant shall be injected downstream of the deaerator, using an individual metering system.
SRU Chlorine Scavenger, Scale Inhibitor and SRU Biocide shall be injected upstream of the SRU,
using an individual metering system.
Inverted Emulsion Breaker shall be injected upstream of the flotation units and the injection points
shall be downstream of hydrocyclones. Use inverted emulsion breaker diluted 10-30 times in fresh
water. Use in-line dilution system or pumps that allow automatic dilution of the product in water, with
no need for tank dilution.
Scale Inhibitor unit for topside shall be prepared to inject the scale inhibitor continuously upstream
of hydrocyclones and other points according to scaling study.
Scale inhibitor injected in the hydrocyclone inlet lines.shall be as near as possible to the water line
outlet of the water discharge equipment (separators and electrostatic treaters).
Separated systems shall be provided, as different products are injected topside and subsea.
18.8.3 Biocide
Shock Biocide and Biostatic shall be injected in the washing tank inlet line. Install the injection point
as near as possible to the liquid line outlet of the 2nd stage degasser.
In units using produced water tanks and slop tanks, provide facilities for Shock Biocide and Biostatic
Injection. Both chemicals shall be injected directly in the water phase of these tanks.
Oil, gas, and water multi-phase export pipelines are included in this item.
Pig launcher and receiver design shall comply with standard specifications.
A launcher-receiver may be used for pipelines operating in two directions (dual-function equipment).
Provide the pig receiving/launching chambers with depressurization facilities, interconnected to the
flare (low and high) system and vent system.
For gas pipelines not allowing liquid delivery to subsequent gas pipelines, consider the possibility of
using a slug catcher to receive liquid slugs from flows originating from cleaning pigging. If the
formation of liquid is not expected, the flow may be directed to the test separator during the stages
of commissioning and start-up of the gas pipeline.
Provide all the pipelines with facilities for launching and receiving at least the low-density foam-type
pig, except for those directed to monobuoys. For pipelines using only foam-type pigging, the
smallest inner diameter shall not be less than 40% of the largest inner diameter.
The recommendation is that all single-phase and multi-phase oil pipelines shall allow at least
conventional type pigging (rigid pig for cleaning).
Lines subject to conventional pigging shall comply with the allowances of the following table:
For all the above-mentioned cases (rigid and foam pig), the inner diameter transitions shall be
beveled with maximum slope of 1:4 (30 ).
For pipes with diameters larger or equal to 16, provide material handling equipment to facilitate
operations with conventional pigs.
All oil pipelines shall allow instrumented pigging except for those that are 100% flexible and those
assigned to monobuoys.
All onshore sections of export oil pipelines shall allow instrumented pigging.
All export oil pipelines interconnected between two SPUs, with no subsea connection with other
branches, shall allow instrumented pigging. In the case of subsea arrangements provided with a
trunk line and branches, the trunk line shall allow instrumented pigging.
All multi-phase oil pipelines shall allow instrumented pigging, except for those that are 100%
flexible.
All multi-phase export oil pipelines with an onshore section shall allow instrumented pigging.
All multi-phase export oil pipelines with uniform inner diameter, interconnected between two SPUs,
shall allow instrumented pigging.
Water pipelines shall allow instrumented pigging, except for those that are 100% flexible.
All the export water pipelines with onshore sections shall allow instrumented pigging.
All gas pipelines shall allow instrumented pigging, except for those that are 100% flexible.
All gas pipelines with onshore sections shall allow instrumented pigging.
All export gas pipelines with operation pressure above 50 kg/cm2, interconnected between two
SPUs, with no subsea connection with other branches, shall allow instrumented pigging. In case of
subsea arrangements with a trunk line and branches operating above 50 kgf/cm2, the trunk line
shall allow instrumented pigging.
19.2.5 Exceptions
Provisional Production Systems or cases not covered in these Guidelines may occasionally
dispense with the use of instrumented pigs with formal approval from the Business Unit Pipeline
Inspection Management.
The variation of the inner diameter of the pipes shall be compatible with the accepted allowances.
Where a subsea interconnection is required for oil pipelines and gas pipelines and instrumented
pigging, use a piggable Y connection (PLEM). In case of pipelines with different diameters, located
at water depth below 300 m, use PLEMs fitted with a subsea pig.
Do not use a gridded T on a PLEM for the interconnection of oil pipelines with convergent flow,
with a smaller diameter (branch) positioned on the upper pipeline generatrix. Use the gridded T
only at the outlet of the secondary tree with a divergent flow to the monobuoy operating with a
conventional tanker vessel, with no foam pig receiver.
Do not use a gridded T in gas pipelines.
20.1. General
When assessing the use of corrosion inhibitors as a treatment alternative, take into account the fluid
velocity limit for each product.
The following notes shall be included in the engineering flow diagrams:
1. Walkways shall be provided for access to the corrosion tester (corrosion coupons and
probes), installed in lines and/or equipment above 1.6 m.;
2. The access connections shall be installed with a minimum free length of 2,0 meters and a
free area with at least 30-cm radius around it, to allow the assembly of the tool used to replace
corrosion coupons and corrosion probes;
3. Except for the access connections of cooling water, heating, and injection systems, install all
the connections on the lower generatrix of the lines, to allow monitoring of the section of water
segregation. When it is not possible to locate the connections on the lower generatrix, locate
them on the upper generatrix, provided that the pipe diameter is not larger than 8 inches. In this
case, use extended stem to allow the coupon to be near the lower generatrix.
Weld the connections for accessing the corrosion testers on the line, and make a hole through them
with a Hot Tape Machine, to allow corrosion monitoring devices to be run (corrosion coupons and
probes), with no interference. Leave only the plugs in the access connections. The corrosion
monitoring devices shall only be installed at the time of the operation startup of the SPU.
Provide at least the following monitoring points, except if corrosiveness studies and proper material
indicates the opposite:
Production Flowlines
Install access connection for the coupon in all the production flowlines, downstream of the
production choke (except for wells with flexible flowlines).
Test Separator
Install access connection for the electric resistance corrosion probe in the test separator oil
inlet. Consider on-line monitoring system, which shall send a signal to an acquisition, analysis,
and alarm system installed in the platform control room.
Gas Compressors
Install two access connections in the gas outlet of each cooler of the compression package,
one for the coupon, and another for the electric resistance corrosion probe. Provide for future
interconnection of on-line monitoring system to the supervisory system.
Install two access connections in the discharge header for the compressors, one for the
coupon, and another for the corrosion probe. Provide for a future interconnection of an on-line
monitoring system to the supervision system.
Gas pipelines
Install at least two access connections in the main gas import and export lines (gas pipelines),
one for the corrosion coupon, and another for the electric resistance corrosion probe,
considering on-line monitoring system for sending the signal to the supervision system. Install
the connections as far as possible from the corrosion inhibitor injection, to allow assessment
of performance.
Provide marinized, ultra-sound thickness metering device on the oil pipeline risers, including in
the submerged portion, when the corrosion study determines the existence of substantially
aggressive fluids.
Oil Pipelines
Install at least two access connections in the main oil import and export lines (oil pipelines),
one for the corrosion coupon, and another for the electric resistance corrosion probe,
considering on-line monitoring system for sending the signal to the supervision system. Locate
the connections downstream, as far as possible from the inhibitor injection point, to allow
assessment of performance.
Provide marinized, ultra-sound thickness metering device on the oil pipeline risers, including in
the submerged portion, when the corrosion study determines the existence of substantially
aggressive fluids.
Seawater Injection System
The standard corrosion monitoring configuration consists of a linear polarization resistance
(LPR) sensor, electric resistance sensor (ER) and galvanic sensor. For this purpose, install
three access connections, downstream of the main injection pumps, 50 cm apart, and
compatible with the 2, high-pressure access systems. To enable automated data acquisition,
interconnect the probes with the corrosion data reading and storage stations, which are
required to feature compatible data transmission outputs for interconnection with the platform
supervision and control system.
CAPTULO: 1 Processo
NDICE
1. OBJETIVO ............................................................................................................................... 90
3. GERAL ..................................................................................................................................... 91
3.1 Planta de Processo ........................................................................................................... 91
3.1.1 Dados de fluido requeridos para as Bases de Projeto................................................ 91
3.1.2 Especificaes de Fluidos Tratados ........................................................................... 92
3.1.3 Nmero de Estgios de Separao e Seleo de Presso/Temperatura de Operao .
................................................................................................................................... 92
3.1.4 Configurao da Planta de Processamento de leo .................................................. 93
3.1.5 Configuraes da Planta de Processo de Gs e Condensado ................................... 99
3.1.6 Dimensionamento de Equipamentos para as Configuraes 1, 2, 3 e 4 .................. 101
3.1.6.1 Degaseificadores .......................................................................................................... 103
3.1.6.2 Separadores de gua Livre .......................................................................................... 103
3.1.6.3 Separadores de Produo ............................................................................................ 103
3.1.6.4 Tratador Eletrosttico (TO) ......................................................................................... 103
3.1.6.5 Separadores Atmosfricos ............................................................................................ 104
3.2 Requisitos Adicionais ...................................................................................................... 104
1. OBJETIVO
2. REFERNCIAS NORMATIVAS
As normas mencionadas no texto so listadas abaixo. Alm disso, deve ser usada a
DR-ENGP-I-1.1 Padres e Regulamentos Tcnicos Aplicados a Projetos.
NRs Normas Regulamentadoras do Ministrio do Trabalho e Emprego
API RP 14C Recommended Practice for Analysis, Design, Installation, and Testing of
Basic Surface Safety Systems for Offshore Production Platforms
OIML-R120 Standard Capacity Measures for Testing Measuring Systems or Liquids Other
than Water
API 4 API MPMS Captulo 4
API STD 617 Centrifugal Compressors for Petroleum, Chemical, and Gas Service
Industries
API STD 619 Rotary Type Positive Displacement Compressors for Petroleum, Chemical,
and Gas Industry Services
API-MPMS 10.4. Manual of Petroleum Measurement Standards
ANP 128 de 08.28.2001 Specification of National or Imported Natural Gas for Domestic
Trade
API-STD-521/ ISO 23251 Guide for Pressure-Relieving and Depressuring Systems
API STD 2000 Venting Atmosphere and Low-Pressure Storage Tanks
BS EN 12874:2001Flame Arresters Performance Requirements, Test Methods and Limits
for Use
AGA No. 3/ No. 9 Orifice Measurement of Natural Gas
AGA No. 7 Measurement of Fuel Gas by Turbine Meters
AGA No. 8 Gas Compressibility and Super Compressibility
ASTM D4057 Standard Practice for Manual Sampling of Petroleum Products
ISO 3170 Petroleum Liquids Manual Sampling
CONAMA 393 Regulamentao de descarte contnuo de gua de processo
DR-ENGP-I-1.6 Diretrizes para Sistemas de Medio de leo e Gs Natural
3. GERAL
Para alcanar um projeto apropriado e uma planta de processo funcional, as seguintes informaes
bsicas so essenciais:
Anlise PVT composicional do fluido representativo (mais de um PVT, se disponvel);
Curvas de produo (leo/gs/gua e/ou gs/condensado/gua) correlacionadas com as
respectivas presses na cabea de poo e na Unidade Estacionria de Produo (UEP), para o
horizonte de produo considerado;
vazo mnima e mxima para cada etapa (compressores includos) ou unidade de processo;
presso de shut-in, maior e menor presso e temperatura de chegada de cada poo produtor na
Unidade Estacionria de Produo (UEP), para cada diferente fase de produo;
demanda estimada de gas lift ao longo do tempo (presso e vazo), quando aplicvel;
presso e temperatura atingidas no sistema de colheta de superfcie aps um perodo de
parada, para cada poo;
propriedades fsicas do leo (viscosidades em trs temperaturas diferentes, temperatura de
deposio de parafina (TIAC), densidade API, ponto de nvoa e tendncia de deposio de
asfaltenos);
teor de contaminantes no gs produzido (CO2, Hg, H2S e outros compostos sulfurados,
compostos aromticos e nitrogenados, onde aplicvel);
Nota: Os Balanos de Massa e de Energia emitidos pelo Projeto Bsico devem conter o teor de
contaminantes previsto para todas as correntes, incluindo o teor compostos oxigenados
(MEG/TEG/etanol) e benzeno;
caracterizao da gua de formao e da gua produzida em testes de formao (se for o
caso);
caractersticas gerais da unidade estacionria de produo (UEP).
As especificaes de fluidos tratados, a serem atingidas, quando aplicvel, devem ser fornecidas:
leo tratado teor de gua e sedimentos (BSW), salinidade, Presso de Vapor Reid (PVR),
temperatura para tanques de armazenamento ou para exportao;
gs tratado a ser exportado, injetado ou usado como gas lift ou combustvel teor de
contaminantes, ponto de orvalho da gua, ponto de orvalho de hidrocarbonetos;
condensado tratado Presso de Vapor Reid (PVR), temperatura, teor de gua;
gua tratada para ser descartada ou injetada teor de slidos, teor de leo e Graxas (TOG),
presso, temperatura e outros, de acordo dom itens 6 e 16 deste documento.
As presses de operao dos estgios de separao devem ser selecionadas baseadas nas
caractersticas do reservatrio e presses esperadas nas cabeas de poos durante a vida til de
produo.
Para gs/condensado e campos com altas RGOs, estudos de reservatrio devem ser feitos para
diferentes contrapresses na instalao de superfcie, levando em conta a possibilidade de duas
diferentes fases de produo, devido queda de presso do campo. Estes estudos devem ser
executados para selecionar a melhor configurao, e as Bases de Projeto devem informar se duas
fases de produo (alta presso / baixa presso) tm que ser consideradas como parte do escopo.
As presses para os estgios subsequentes devem ser escolhidas de acordo com a otimizao e
padronizao do processo/compressores e levando em considerao qualquer outra unidade de
processo intermediria requerida para tratar o gs produzido (ponto de orvalho de hidrocarbonetos
e remoo de contaminantes).
A temperatura no primeiro estgio de separao deve ser adequada para permitir uma separao
apropriada de fases; o aquecimento do fluido deve ser sempre considerado. Isto tambm
requerido para campos de gs/condensado, e a possibilidade de formao de parafina tambm
deve ser levada em conta.
A seleo de temperaturas para processamento de leo deve ser baseada em:
testes de laboratrio para separao gravitacional no primeiro estgio.
testes de laboratrio para tratamento eletrosttico de leo. Estes testes devem ser
realizados com e sem gua de diluio.
O fluido de produo de chegada deve ser aquecido. Sempre que possvel, deve ser feita a mistura
do fluido de chegada com gua produzida em alta temperatura, proveniente do segundo e terceiro
estgios, na entrada do primeiro estgio de separao. Trocadores de calor devem ser evitados a
montante do primeiro separador. Durante a fase inicial de produo, quando gua produzida ainda
no est presente, leo deve ser usado como fluido de aquecimento para a mistura, usando o
mesmo circuito de tubulao. No caso de campos de gs/condensado, diferentes configuraes
so possveis.
Figura 1 Configurao 1
Figura 2 Configurao 2
Figura 3 Configurao 3
As figuras 5, 6 e 7 descrevem o esquema geral de processo para uma planta de processo offshore
para gs/condensado, com diferentes destinos para o condensado (gasoduto ou tanques de
carga). As figuras 6 e 7 incluem uma etapa de compresso principal.
Dependendo das caractersticas especficas do campo de gs/condensado, algumas
unidades/operaes de processamento podem no ser requeridas ou podem estar numa
sequncia diferente. As Bases de Projeto devem indicar se um sistema de compresso deve ser
includo, mesmo se necessrio somente em uma fase posterior do desenvolvimento do campo,
quando o gs/condensado chega UEP com uma presso mais baixa.
Nos casos de Unidades produzindo poos de leo e poos de gs/condensado, a alternativa de
produo dos poos de gs/condensado somente em baixa presso deve sempre ser considerada.
Neste caso, o gs associado proveniente da separao do leo e o gs no-associado dos poos
de gs/condensado so coletados pelo mesmo sistema de compresso principal.
Outra possibilidade considerar a conexo da produo de gs/condensado em alta presso no
sistema localizado na descarga dos compressores principais, para aproveitamenteo da fase de alta
presso.
O processamento de gs/condensado deve englobar as seguintes etapas principais:
inibio de hidratos em sistemas de coleta at chegar na superfcie;
quebra de presso (choke) at o primeiro estgio de separao;
primeiro estgio de separao, mais provavelmente em altas presses;
aquecimento da fase lquida do 1 estgio de separao, para melhoria da separao
hidrocarboneto/gua ou hidrocarboneto/soluo de MEG, se aplicvel;
Unidades de tratamento de gs de produo (remoo de gs cido e desidratao)
desidratao de condensado e bombeamento para exportao atravs de gasoduto ou
tratamento do condensado para armazenamento;
Unidade de Regenerao de MEG (ver item 10.5);
Tratamento e descarga de gua produzida (onde aplicvel).
O condensado do separador de alta presso do primeiro estgio deve ser direcionado para uma
Unidade de Desidratao de Condensado, a fim de se atingir o teor de gua especificado.
O atendimento especificao da Presso de Vapor Reid do condensado (PVR) requerido
apenas quando o condensado ser armazenado em tanques de carga.
Deve ser especificado nas Bases de Projeto se a estabilizao do condensado faz parte do escopo
do projeto offshore ou se ser realizada no continente.
C ON F I G. 2
T R A T A M EN T O S EP A R A O
( C OM T A N QU E D E S EP A R A O GR A VI T A C I ON A L
EL ET R ET R OS T T I C O A T M OS F R I C A
L A VA GEM )
D i m e n s o N me r o S EP A R A D OR D E S EP A R A D OR D E S EP A R A D OR
D EGA S EI F I C A D OR P R - T O TO
( x LTT) de Tr e ns GU A L I VR E P R OD U O A T M OS F R I C O
1 t rem QL 15 0 . 0 0 0 b p d Qo 10 0 . 0 0 0 b p d
3 , 7 m x 11 m
15 0 . 0 0 0 < QL 10 0 . 0 0 0 < Qo
2 t r ens
3 0 0 . 0 0 0 bpd 3 0 0 . 0 0 0 bpd
S e r e que r i do 2
Tr e ns TO
3 , 7 m x 13 m 2 t r ens
E
QL 2 0 0 . 0 0 0 b d p
S e r e que r i do 1 S e r e que r i do 1
Tr e m de Tr e m de
1 t rem
S e pa r a o S e pa r a o
Gr a v i t a c i o n a l Gr a v i t a c i o n a l
4 , 3 m x 15 m
S e r e que r i dos 2 S e r e que r i dos 2
Tr e ns de Tr e ns de
2 t r ens
S e pa r a o S e pa r a o
Gr a v i t a c i o n a l Gr a v i t a c i o n a l
15 0 . 0 0 0 < QL
4 , 3 m x 16 m 1 t rem
3 0 0 . 0 0 0 bpd
S e r e que r i do 1 S e r e que r i do 1
Tr e m TO Tr e m TO
1 t rem
E E
QL 2 0 0 . 0 0 0 b d p QL 2 0 0 . 0 0 0 b d p
4 , 3 m x 19 m
S e r e que r i do 2 S e r e que r i do 2
T r e n s T O OU T r e n s T O OU
2 t r ens
2 0 0 . 0 0 0 < QL 2 0 0 . 0 0 0 < QL
3 0 0 . 0 0 0 bpd 3 0 0 . 0 0 0 bpd
S e r e que r i do 1 S e r e que r i do 1
Tr e m de Tr e m de
1 t rem
S e pa r a o S e pa r a o
Gr a v i t a c i o n a l Gr a v i t a c i o n a l
4,3 m x 22 m
S e r e que r i dos 2 S e r e que r i dos 2
Tr e ns de Tr e ns de
2 t r ens
S e pa r a o S e pa r a o
Gr a v i t a c i o n a l Gr a v i t a c i o n a l
3.1.6.1 Degaseificadores
Para os casos com vazo mxima de produo de lquido at 150.000 bpd, para os
Degaseificadores da Configurao 2 (Com Tanque de Lavagem) deve ser previsto um trem de
Degaseificador com dimenses de 3,7 x LTT 11 m.
Para os casos com vazo mxima de produo de lquido entre 150.000 bpd e 300.000 bpd, devem
ser previstos dois trens com dimenses de 3,7 x LTT 11 m. Alternativamente, um trem de
Degaseificador com dimenses de 4,3 x LTT 16 m pode ser utilizado.
As dimenses de 4,3 x LTT 19 m devem ser adotadas para separadores de gua livre da
Configurao 1 (com dessalgao) e configurao 3 (sem dessalgao).
O nmero de trens de produo deve ser igual ao nmero de trens da separao eletrosttica.
Para os casos com vazo mxima de produo de lquido at 200.000 bpd, um ou dois trens de
produo devem ser usados, dependendo do resultado da seleo para o nmero de trens de
tratadores eletrostticos. Para os casos com vazes de produo de lquido entre 200.000 bpd e
300.000 bpd, dois trens de produo devem ser usados, tanto para os separadores de gua livre,
como para os separadores de produo e para os tratadores eletrostticos.
Para vazes mximas de produo de lquido at 200.000 bpd, um trem de separador de produo
com dimenses de 4,3 x LTT 19m deve ser previsto, no caso de selecionar um trem de tratador
eletrosttico. Caso dois trens de tratadores eletrostticos sejam necessrios, dois trens de
separador de produo com dimenses 4,3 x LTT 13m devem ser adotados.
Para vazes de lquido entre 200.000 bpd e 300.000 bpd, dois trens de separador de produo com
dimenses de 4,3 x LTT 19 m devem ser adotados.
Somente as dimenses de ( 4,3 x LTT 15m) ou ( 4,3 x LTT 22m) so permitidas para o Pr-TO
e para o TO. O nmero de trens de Pr-TO deve ser igual ao nmero de trens de TO. Os nmeros
de trens do separador de gua livre e do separador de produo tambm devem ser iguais ao TO.
A escolha de uma das dimenses dentre as opes da Tabela 1, para o Pr-TO e para o TO, deve
ser uma funo da possvel temperatura de tratamento e da vazo, ambos os quais dependem do
escoamento e do tipo de leo a ser processado. A vazo, tanto para o Pr-TO como para o TO,
deve ser inferior ou igual vazo mxima permitida para cada um destes tratadores.
Para o dimensionamento do Pr-TO e do TO, deve ser testada inicialmente uma temperatura de
operao inferior ou igual a 100C. Caso as dimenses e o nmero de trens excedam os valores
disponveis na Tabela 1, uma temperatura inferior ou igual a 120C deve ser testada. Caso as
dimenses e o nmero de trens ainda excedam os valores disponveis na Tabela 1, a temperatura
at 130C deve ser permitida, exigindo, neste caso, a utilizao de materiais especiais nos vasos.
As dimenses de 3,7 x LTT 11 m devem ser adotadas para separadores atmosfricos. Para
vazes de leo at 100.000 bpd, um nico trem deve ser adotado.
Para casos com vazo mxima de produo de leo de 100.000 bpd, para os separadores
atmosfricos de qualquer configurao de planta de tratamento de leo, um trem de separador
atmosfrico deve ser adotado.
Para casos com vazo mxima de produo de leo entre 100.000 bpd e 300.000 bpd, dois trens
de separadores atmosfricos devem ser adotados.
Os dimetros internos de conexo dos risers (exportao de gs, gas lift, injeo de gs),
geralmente seguindo os padres API, devem ser compatibilizados com a tubulao da planta da
Unidade, geralmente ANSI B31.3, de forma a evitar restries para operaes de pig
(convencional, esfera ou instrumentado).
Todos os sistemas que requerem pigagem devem ser claramente informados nos documentos das
Bases de Projeto.
As Bases de Projeto devem informar, alm das condies de shut-in, a maior e a menor presso e
a maior e a menor temperatura de chegada de cada poo na plataforma, para condies normais
de escoamento e para reinicializao da produo aps shutdown, bem como o local onde estes
valores se referem.
O material da tubulao de superfcie e dos acessrios a jusante das vlvulas chokes dos poos
deve ser especificado para a mnima temperatura atingida a jusante do dispositivo de quebra de
presso, considerando a repartida aps uma parada de poo por um certo perodo.
4.1 Geral
Devem ser previstas Instalaes para pigagem de todas as linhas de escoamento provenientes da
rvore de Natal Molhada dos poos produtores ou dos manifolds de produo submarina, mesmo
que os estudos de garantia de escoamento no indicquem a possibilidade de formao de
depsitos orgnicos nas linhas de produo.
As instalaes para deslocamento de pig devem prever o uso de gs e diesel.
Quando indicada a utilizao de tubo flexvel, instalaes na chegada de cada linha de escoamento
do poo devem ser previstas, antes da primeira curva, para permitir a operao do mesmo.
O Projeto Bsico deve determinar o envelope de formao de hidratos para cada linha de produo
dos poos, para assegurar que as condies de operao de todos os poos (escoamento normal
e parada) esto fora da regio de formao de hidratos. Se os hidratos so provveis de ocorrer
sob condies de escoamento, algum mtodo de preveno de hidrato deve ser adotado.
As alternativas a serem consideradas so:
injeo contnua de inibidor de hidrato a montante da choke de cada cabea de poo;
coleta de fluidos a alta presso, evitando dispositivos de quebra de presso submarina e
efeitos JT. Neste caso, a quebra de presso (choke) da cabea de poo est localizada nas
instalaes de superfcie, permitindo um melhor controle da injeo de inibidor, alm de
melhorar e minimizar efeitos emulsionantes.
Para poos produtores, transmissor de presso e temperatura de fundo de poo digital, PDG
(permanent downhole gauge) ou equivalente, deve ser previsto sempre que possvel, a critrio da
Engenharia de Reservatrios.
Nos anulares dos poos produtores, quando gas lift empregado, deve ser instalado PT com
indicao no sistema de superviso.
O material dos internos das chokes, para poos de campos de rochas no consolidadas sem
gravel, deve ter dureza para suportar alta abraso (ligas de tungstnio).
Devem ser instalados PDIs nas correntes quentes e frias dos permutadores de calor. Tambm
devem ser previstos indicadores de presso e temperatura a montante e a jusante de cada
permutador de calor no sistema de superviso, diretamente (prximo ao permutador de calor) ou
indiretamente (localizado em outro equipamento, como por exemplo bomba, compressor, vaso,
separador etc.)
Prever by-pass individual para cada permutador a fim de permitir a limpeza e manuteno dos
mesmos.
Dependendo da aplicao, o Projeto Bsico pode selecionar trocadores de placas (PHE),
trocadores de circuito impresso (PCHE) ou trocadores casco e tubos.
Quando forem usados trocadores de placas, devem ser previstas instalaes para alimentao de
diesel, de forma a substituir o fluido em caso de paradas, evitando deposio orgnica nas placas.
O Projeto Bsico dever avaliar a melhor forma de proteo para evitar a contaminao da planta
de processo com o sistema de diesel, utilizando preferencialmente um sistema dedicado.
Pontos de amostragem devem ser instalados ao longo do costado dos vasos separadores
(separador de gua livre, teste, produo e tratador eletrosttico) na regio de interface gua-leo.
Prever linhas para despressurizao e/ou drenagem dos filtros e FQIS que operam com
hidrocarbonetos lquidos, encaminhando-os para os coletores de vent atmosfrico e drenagem
aberta oleosa.
Prever figura 8 em todas as entradas e sadas com dimetro maior que 4, a fim de facilitar as
paradas para manuteno dos equipamentos.
O Projeto Bsico deve avaliar a recuperao das correntes de gs resultantes de eventuais
operaes de despressurizao, tais como coletor de gs lift, anular do poo, gasoduto de
exportao e qualquer equipamento da planta de processo, direcionando cada corrente de gs
para um sistema apropriado, conforme as condies de presso e temperatura.
Para campos com previso de produo de areia, devem ser previstas conexes para o sistema
side-stream nos vasos separadores para remoo de areia e sedimentos.
Deve ser instalado um carretel, individual por trem de produo, prximo e a montante da vlvula
de bloqueio do primeiro vaso separador, para possibilitar a futura instalao de vlvula de
amortecimento de golfada, se necessrio. Conexes reservas analgicas de automao, um par
para cada trem de produo, devem ser previstas no painel de entradas/sadas (I/O) mais prximo
do local. Caso haja a expectativa de ocorrncia de golfadas deve-se prever o uso de Controle por
Bandas para o controle de nvel dos vasos separadores de produo.
Quando houver indicativo que a carga a ser processada apresenta tendncia para formao de
espuma, deve ser avaliada a instalao de dispositivos de separao ciclnica para quebra de
espuma na entrada dos separadores.
As tomadas de injeo de anti-espumante devem ser localizadas o mais distante possvel do
separador, de modo a se obter maior tempo de contato.
Para quebra de espuma deve ser instalado um dispositivo defletor tipo ciclnico, o com fixao
atravs de parafusos, para permitir sua manuteno.
Devem ser instalados dispositivos para remoo de nvoa da fase gasosa, tipo demister (knited
wire mesh) ou ciclnico ou dispositivo tipo aleta (vane) dotado de anteparas defletoras internas.
Devem ser previstas facilidades para remoo destes internos para fins de limpeza e manuteno.
Devem ser instalados dispositivos anti-vrtice tipo placas em cruz nas linhas de sada de leo e
gua.
Deve ser avaliada a instalao de dispositivos quebra-ondas em plataformas flutuantes e navios.
O separador de teste deve ser trifsico, com medio de todas as fases; isto tambm vlido para
Unidades de campos de gs/condensado.
O separador de teste deve ser projetado considerando o padro de escoamento de cada poo e o
possvel acmulo de lquido na linha de produo (hold-up). Um aquecedor de teste deve ser
instalado, a montante do separador de teste.
Prever interligao da linha de sada de gs do separador de teste com o sistema de alvio de baixa
ou alta presso, com controle de presso (PC/PV), de modo a permitir que o separador de teste
opere a presses muito baixas.
Prever a instalao de FQIs a jusante das bombas dos separadores de teste, de modo a evitar a
cavitao das mesmas, no caso de utilizao de medidores intrusivos. Os FQIs devem ser
instalados a jusante da FV, evitando que o leo do refluxo volte a ser computado, e a montante da
LV, evitando que o gs liberado nesta vlvula acelere o medidor, de modo a evitar medio irreal e
possvel dano dos FQI.
Deve ser previsto, na sada de leo, analisador de BSW em linha. Aps a medio, o leo deve ser
bombeado para o processo, a montante do pr-aquecedor e a gua deve ser bombeada para a
planta de tratamento.
Quando houver necessidade de recursos para calibrao fiscal, deve ser considerado o disposto na
DR-ENGP-I-1.6 Diretrizes para Sistemas de Medio de leo e Gs Natural.
operao deve ter uma lmpada piloto, em paralelo com o voltmetro, para funcionar como um
indicador de campo, mostrando que se o transformador est operando adequadamente ou no.
Com o objetivo de prevenir contaminao do leo isolante do transformador e de modo a prevenir
o efeito corona, devem ser providenciados mtodos eficientes de selagem e deteco de
vazamento nos dutos entre as buchas e cada transformador, alm de alarme remoto de
vazamento, desligando o(s) transformador(es) em caso alarme.
A cmara do transformador, do seletor de TAP e do terminal do secundrio devem possuir
indicadores locais de nvel de leo. Um painel local com indicao de corrente e tenso, alm de
um disjuntor, devem ser instalados no circuito primrio de alimentao do transformador, para
isolar o sistema do barramento energizado durante manuteno do tratador. Tambm deve ser
fornecido um cadeado para travamento da chave, nas posies ligado e desligado.
As buchas de entrada e isoladores devem ser feitas de resina com aplicao provada em campo
para servio semelhante.
A resina deve ser nova, nenhuma resina reprocessada deve ser usada. O material da bucha de
entrada e dos isoladores deve ser feito pelo processo de compresso.
Testes de certificao de resina, como raio X, massa especfica e testes de penetrao devem ser
realizados para a bucha de entrada e o isolador.
A manuteno da bucha de entrada deve ser realizada externamente ao vaso, sem a necessidade
de acesso interno ao mesmo.
Deve ser garantida uma margem de segurana entre o NPSH requerido e o disponvel de pelo
menos 1 metro para as bombas de transferncia.
As bombas booster e principais devem possuir reserva, sendo que a configurao final deve ser
analisada caso a caso em funo da instalao e da curva de produo.
Quando a altura manomtrica total do sistema de bombeamento ultrapassar 50 kgf/cm, a altura
manomtrica deve ser bem distribuda entre as bombas booster e principais, de forma a permitir a
transferncia de leo com vazes menores operando somente as bombas booster e com as
bombas principais desligadas. Esta situao ocorre no incio da vida produtiva e na partida aps a
parada de emergncia (entrada gradativa dos poos) e no final da vida produtiva do campo
(declnio de produo de leo com aumento de BSW).
Caso no hajam outras especificaes claras nas Bases de Projeto, o leo tratado a ser
armazenado em tanques deve ser previamente resfriado, de forma que sua Presso de Vapor Reid
(PVR) seja menor ou igual a 10 psia, garantindo a total estabilizao do leo (esta restrio PVR
tambm vlida quando condensado de gs incorporado ao leo nos tanques). O leo tambm
deve ser especificado para BSW 0,5 %, salinidade 285 mg/L (95 ptb) e teor de H2S 1 mg/Kg.
A anlise do BSW deve seguir o API-MPMS 10.4; a anlise de salinidade deve seguir o ASTM
D3230; a anlise de H2S deve seguir o UOP 163-89 e a ISO 6326-3.
Deve ser instalada uma rede com vlvulas acionadas remotamente para a distribuio do leo para
os tanques de carga, de forma que o enchimento dos tanques seja independente das operaes de
descarga e limpeza dos tanques.
O alinhamento de volumes de hidrocarbonetos diretamente para os tanques de carga sem medio
fiscal no aceitvel; este requisito inclui qualquer volume de leo e de condensado dos tambores
de knock-out do sistema de flare, dreno fechado (se aplicvel), rejeito dos hidrociclones e dos
flotadores e outros.
Deve ser prevista facilidade para utilizao de leo tratado, j especificado conforme o item 5.4,
para operaes de preveno de hidrato em linhas de escoamento. Em caso de parada do poo
(prevista ou no programada), o projeto deve considerar que as facilidades disponveis para
circulao de leo tratado (interligao do sistema de leo com o sistema de servio, acessrios,
aquecimento, etc) deve estar disponvel para utilizao imediata. A utilizao de diesel para essa
funo dever continuar existindo como alternativa ao leo tratado que dever ser o caso base.
Deve ser avaliada a necessidade de mistura entre o diesel e o leo tratado assim como a
necessidade de aquecimento do leo. Deve ser prevista medio de vazo do leo para
determinao dos volumes utilizados. Deve ser avaliada a viabilidade de utilizao de um sistema
de medio fiscal, considerando o risco da ANP (Agncia Nacional de Petrleo, Gs Natural e
Biocombustveis) no aprovar o desconto do leo utilizado (j medido de forma fiscal) dos volumes
fiscais produzidos, caso se utilize um sistema de medio operacional.
6.1 Geral
O descarte de gua produzida deve ser atravs de uma tubulao dedicada ou tubo de despejo
(caisson), segregado das demais drenagens.
A extremidade da tubulao de descarte de gua produzida deve estar abaixo da superfcie do
mar.
Caso esta configurao no seja usada, a margem a ser aplicada capacidade dos hidrociclones
dedicados aos tratadores eletrostticos deve ser valiada durante o Projeto Bsico.
Deve ser avaliada a alternativa de remoo do gs liberado a jusante da LV dos separadores de
produo ,atravs de um vaso degaseificador ou diretamente no flotador.
A gua oriunda do separador de teste deve ser direcionada para montante do sistema de
aquecimento de leo ou para o separador de gua livre ou para o primeiro estgio de
degaseificao.
Prever controle da taxa de rejeito dos hidrociclones atravs da razo do diferencial de presso, via
sistema supervisrio.
Os hidrociclones devem prever abertura do cabeote de entrada para limpeza interna.
Os liners devem ser alinhados por grupo de liners, de forma a permitir o alinhamento sem abertura
dos vasos.
Devem ser previstas tomadas isocinticas para coleta de amostras na sada de gua dos
separadores de 1 estgio e dos tratadores eletrostticos, na entrada e na sada dos hidrociclones
e do flotador, na sada do vaso degaseificador e na entrada dos tubos de despejo (caissons) ou
dos tanques de drenagem aberta.
Deve ser prevista a instalao de medidor de TOG online no descarte de gua produzida. As
tecnologias aceitveis so fluorescncia induzida de laser e espalhamento de luz. Nos casos em
que a fase leo for composta exclusivamente por condensado, a tecnologia de espalhamento de
luz deve ser preferida. O sistema deve possuir instalaes para limpeza automtica das lentes e
condicionamento de amostra.
A linha de entrada de gua oleosa, de cada hidrociclone, deve ser interligada com sua sada de
rejeito, atravs de uma linha equipada com vlvula de bloqueio tipo esfera, para as operaes de
retro-lavagem.
Os flotadores devem ser do tipo gs dissolvido ou induzido hidraulicamente. No devem ser
utilizados flotadores tipo sparger.
O Tempo de residncia da unidade de flotao deve ser de, no mnimo, 10 minutos.
Um ou dois tanques de carga do FPSO devem ser projetados como Tanque Offspec. Estes
tanques recebem correntes de gua e de leo fora de especificao, devido m performance
temporria das plantas ou algum equipamento fora de operao. Estes tanques devem ter uma
capacidade mnima de 10.000 m cada, devem ser totalmente revestidos ou pintados e
especificados de acordo com as condies de operao das plantas de processo e no deve ser
adjacentes. Os fluidos recuperados dos Tanques de Slop podem tambm ser alinhados para os
Tanques Offspec. Os Tanques Offspecno devem ser conectados aos tanques de Carga nem ao
sistema de offloading. Aps um certo tempo de residncia, as fases tendem a se segregar e a
nica opo para ambas as fases (leo e gua) o retorno para a planta de processo
correspondente.
Uma derivao em T (spool com vlvula de bloqueio e flange cego) deve ser instalada na descarga
das bombas da fase aquosa (no topside), de modo a permitir operaes de offloading no futuro, ou
em situaes de contingncia.
As demais correntes de gua segregada, quais sejam: gua de teste de estanqueidade de
mangotes, gua de lavagem de mangotes, gua de lavagem de tanques, gua de raspagem de
tanques, devem ser enviadas para os Tanques de Slop.
A capacidade dos Tanques de Slop deve ser conforme definido no item 5.6 da DR-ENGP-II-P2-2.2
Critrios Gerais para Sistemas de Cascos para FPSO-FSO, respeitando o valor mnimo de 5.000
m para cada um dos tanques (slop sujo e slop limpo).
Todos estes tanques que iro manusear gua produzida e gua segregada devem ser preparados
para ambiente corrosivo e devem prever instalaes para controle da gerao de H2S. Deve ser
prevista a instalao de sensores de H2S nas reas confinadas onde passam as tubulaes que
manuseiam gua dos Tanques de Slop e dos Tanques Offspec do navio.
7. SISTEMA DE DRENAGEM
7.1 Definies
7.2.1 Geral
Nenhuma comunicao ser permitida entre o sistema de esgoto da embarcao e o sistema de
drenagem da planta.
Determinar na elaborao do projeto para as linhas de drenagem aberta e/ou fechada nas
plataformas semi-submersveis, se, devido aos movimentos da embarcao (roll, pitch e heave),
haver uma alimentao reversa de leo dos coletores para as canaletas e/ou equipamentos,
devido ao pequeno ngulo de inclinao dos coletores.
dimensionado para atender a rea cuja vazo de gua para o sistema de dilvio seja a maior
dentre as previstas no projeto. Somar a vazo de hidrante ao valor acima.
Para no superdimensionar o tubo de despejo de reas no classificadas, no caso de dilvio
ou chuva forte, a vazo excedente deve ser direcionada par o mar.
Todos os bocais de dreno fechado devem ter duas vlvulas de bloqueio com flanges cegos.
7.3.1 Geral
No ser permitida a comunicao entre o sistema de esgoto da embarcao e o sistema de
drenagem da planta.
No projeto das linhas de drenagem abertas e/ou fechadas em FPSO e FSO deve ser verificado se,
devido aos movimentos da embarcao (roll, pitch, heave, trim e heel), no haver retorno de leo
dos coletores para os drenos e/ou equipamentos, devido ao pequeno ngulo de caimento dos
coletores.
No interior de turret, quando forem includos recebedores/lanadores ou equipamentos que
manuseiam hidrocarbonetos, deve ser previsto um sistema de coleta de drenagem aberta
classificada oleosa.
O lquido recuperado no tanque de drenagem aberta classificada oleosa do turret deve ser
direcionado para o manifold localizado no turret.
As plataformas fixas devem possuir flanges, no compartimento da bomba dos tubos de despejo, de
modo a ajustar a altura de interface do leo com as variaes de nvel decorrentes da instalao da
jaqueta.
Prever boca de visita/inspeo no tubo de despejo.
Prever tomadas de amostra nas linhas de descarga da bomba do tubo de despejo de reas
classificadas e nos tanques de drenagem com separao gua/leo.
No ser permitida a instalao de vaso com a finalidade de recuperao de leo a partir de gs
pressurizado (blow case vessel) em substituio bomba do tubo de despejo em caso de falha da
bomba.
9. SISTEMAS DE COMPRESSO
9.1 Geral
9.4 Despressurizao
Todos os estgios de compresso devem possuir um vent com duplo bloqueio (agulha+esfera ou
globo+esfera) e flange cego para despressurizao final da mquina (liberao para manuteno)
para um local seguro.
Deve ser avaliada a necessidade de temporizao das BDV do sistema de despressurizao
durante as fases de projeto.
Um orifcio de restrio deve ser instalado a jusante da BDV para melhor ajuste da vazo de
No caso de gs com alto teor de CO2, a formao de slidos deve ser estudada de formar a
garantir que nenhuma obstruo ocorrer a jusante dos dispositos de alvio/despressurizao.
O Projeto Bsico deve definir um comprimento de tubulao a montante do dispositivo de
despressurizao (RO) com material apropriado para manter a condio de operao normal (alta
presso e alta temperatura), assim como a condio de despressurizao (baixa presso e baixa
temperatura).
Nos casos onde o condensado ser armazenado em tanques de carga, este deve ser conectado
corrente de leo, a montante dos estgios de baixa presso, de modo a ser gerado um produto
nico, com a PVR ajustada. Neste caso, a fase de desidratao no requerida. O tratamento
mais adequado do condensado deve ser definido nas Bases de Projeto.
O Projeto Bsico deve considerar, como regra geral para destino de condensado, enviar o lquido
proveniente de cada vaso do processo a um vaso cuja presso de operao imediatamente
inferior.
Para a recuperao de condensado dos vasos de processo deve ser adotada a seguinte filosofia:
o lquido eventualmente coletado no vaso depurador a montante da torre de deidratao
(Unidade de Desidratao) deve ser direcionado para um separador, de acordo com as
condies de operao;
o lquido proveniente dos vasos da unidade de controle de ponto de orvalho de
hidrocarbonetos deve ser encaminhado para um estgio da planta de leo, de acordo com
as condies de operao;
o lquido proveniente Depurador de Gs Geral deve ser encaminhado para um estgio da
planta de leo, de acordo com as condies de operao;
o condensado proveniente da descarga do vaso depurador de cada estgio de compresso
deve ser encaminhado para a entrada do vaso depurador do estgio anterior;
o condensado proveniente do vaso depurador na suco da Unidade de Recuperao de
Vapor deve ser encaminhado para o Vaso de Blow Down do sistema de tocha.
10.1 Geral
Remoo de H2O;
Remoo de CO2;
Remoo de H2S;
Remoo de hidracarbonetos pesados;
Uma combinao de alguns ou de todos os itens acima.
Para fins de projeto, um range dos contaminantes de entrada deve ser considerado, bem como as
capacidades mnima e mxima. Os casos de projeto devem ser claramente apresentados nas
Bases de Projeto.
A soluo de TEG efluente do vaso de expanso deve ser automaticamente controlada e passar
atravs de um filtro de cartucho, em seguida por um filtro de carvo ativado para remoo de
produtos de degradao, seguido por outro filtro de cartucho para remoo de slidos, e finalmente
encaminhada para o processo de regenerao da soluo.
Deve ser avaliada a injeo de gs tratado de stripping no refervedor de glicol, por meio de um
distribuidor no refervedor ou por coluna de stahl. Prover medio na vazo do gs de stripping.
O refervedor de glicol deve ser do tipo resistncia eltrica, com controle de temperatura eletrnico;
prover aquecimento em estgios e dissipao de calor em caixas prova de exploso. Deve ser
utilizado um sistema de encamisamento, dotado de resistncias eltricas sobressalentes, que
permita a troca de resistncias sem a necessidade de drenagem do sistema de glicol. O clculo da
carga trmica deve levar em considerao a perda de condutividade trmica provocada por este
encamisamento.
A unidade deve prever um vaso para drenagem, armazenamento e reposio de glicol. Este vaso
deve ter capacidade de armazenamento apropriada (capaz de receber a drenagem do
equipamento com o maior inventrio, no mnimo). O abastecimento de glicol deve ser feito por
gravidade e deve ser previsto um transmissor de nvel (LT), interligado ao sistema supervisrio.
A tubulao de TEG desde a sada do refervedor at a suco da bomba deve ser dimensionada
para TEG frio, devido ao aumento de viscosidade e maior perda de carga associada.
Deve ser instalada uma SDV entre a descarga da bomba e a torre absorvedora a fim de evitar o
retorno de gs durante eventos de shutdown.
O resfriador TEG/gua pode ser do tipo casco-tubo ou de placas soldadas, e deve ser localizado a
jusante da bomba de glicol, com indicao de temperatura das quatro correntes. Os trocadores
glicol/glicol devem ser do tipo placas.
No projeto da torre absorvedora, a temperatura de entrada do gs deve ser a menor possvel,
limitada pelo approach com o fluido de resfriamento.
A temperatura de entrada do glicol deve ser de 5 a 10C superior temperatura de entrada do gs
na torre, para evitar condensao de hidrocarbonetos e a formao de espuma. Prever
monitoramento e controle da diferena de temperatura de entrada do gs e do glicol.
A linha de vent da unidade de regenerao no deve ter pontos baixos, a fim de evitar contra
presso no vent da torre. A linha de vent deve ser direcionada para uma rea independente e
segura, no compartilhada com outros vents e provida de corta-chama.
Prever TEG vent trap para remoo de lquido e coleta de amostra, instalado o mais distante
possvel da torre de TEG.
As bombas de glicol devem ser do tipo deslocamento positivo. As bombas devem ser
independentes por torre absorvedora, com reserva comum.
Para medio de vazo de TEG circulante, utilizar medidor tipo deslocamento positivo
(engrenagem oval).
As seguintes variveis devem ter seus valores disponveis no sistema de superviso: vazo de
glicol circulante, vazo de gs de stripping, temperaturas de entrada e sada de gs da torre
absorvedora, temperatura do recheio da torre absorvedora, temperatura do glicol na entrada da
absorvedora, temperatura do refervedor, temperatura do topo da torre regeneradora, presso da
torre regeneradora, presso do vaso de descarga e nvel de todos os vasos.
Um sistema de controle de injeo de qumicos para ajuste de pH deve ser previsto,
preferivelmente usando MEA, MDEA ou outra amina neutralizante.
Uma camada de leito de guarda deve ser includa na parte superior do leito de cada vaso de
peneiras moleculares.
sistemas, um para remoo de gua livre usando filtros coalescedores, e outra para remoo de
gua dissolvida usando stripping com gs desidratado. gua emulsionada pode ser removida em
qualquer um desses sistemas.
Tecnologias adicionais, como peneiras moleculares e adsoro por alumina ativada, podem ser
avaliadas para remoo de gua dissolvida.
A especificao do teor de gua na corrente de condensado desidratado e na corrente de gs, se
exportados juntos, deve ser estabelecida nas Bases de Projeto, com base na anlise de todo o
envelope das condies de presso e temperatura.
Pelo menos as seguinte variveis devem estar disponveis no sistema de superviso: temperaturas
do condensado de entrada e sada da coluna de stripping, presso da coluna de stripping, vazo de
condensado e temperatura, vazo e presso do gs de stripping.
Caso a injeo contnua de inibidor de hidrato (soluo MEG) tenha sido selecionada como mtodo
de preveno de formao de hidratos em poos de gs/condensado, uma Unidade de Tratamento
de MEG (regenerao e reclaiming) deve ser requerida nas Bases de Projeto.
A capacidade de armazanamento de MEG rico deve ser, no mnimo, igual capacidade de
armazenamento de MEG pobre mais a quantidade mxima de gua produzida, de acordo com as
simulaes de reservatrio.
Os tanques de MEG rico e pobre devem ser divididos internamente em dois tanques, para permitir
limpeza adequada.
A concentrao da soluo de MEG pobre requerida deve ser estabelecida de acordo com estudos
de garantia de fluxo.
As seguintes diretrizes devem ser consideradas para a seo da planta a montante da Unidade de
Tratamento de MEG:
De acordo com o item 3.1.3 Nmero de estgios e seleo das presses/temperaturas de
operao, aquecimento do fluido de entrada da UEP geralmente necessrio. De forma a
otimizar a separao de hidrocarbonetos proveniente do MEG rico a montante da unidade
de MEG, fluidos de entrada devem ser aquecidos a uma temperatura mnima de 40C. O
tempo de residncia mnimo e valores de temperatura ideiais devem ser determinados
atravs de testes laboratoriais de formao de emulso;
O MEG rico proveniente do separador de alta presso deve ser flasheado para um estgio
de separao de baixa presso, para que o gs seja liberado;
Como possvel ter slidos provenientes de poos, filtros de slidos (como filtros de
mangas e de cartucho) devem ser previstos para a corrente de MEG rico;
O polimento final da corrente completa de MEG rico deve ser realizado com filtro de carvo
vegetal, seguido por outro filtro para remoo das partculas de carvo vegetal;
O sistema de filtragem deve estar localizado na seo de baixa presso da Unidade; a
capacidade do tanque de armazenamento de MEG pobre deve ser capaz de permitir injeo
contnua de MEG pobre durante, no mnimo, 1 dia de operao, em caso de parada da
unidade de regerao de MEG;
Todos equipamentos que possam precisar de limpeza frequente devem ser previstos com
um reserva. A tubulao da unidade deve ter carretis flangeados, flanges de espera e
dispositivos para facilitar a operao de limpeza;
Instrumentos de medio de vazo devem ser instalados na:
Corrente de entrada de MEG rico na unidade de MEG;
Correntes de reciclo e corrente de gua produzida;
Corrente de MEG pobre;
Corrente by-passada da seo de reclaiming, quando aplicvel.
A necessidade de instalao de uma unidade de remoo de CO2 e/ou H2S deve ser definida nas
Bases de Projeto. Para gs produzido contendo H2S, a especificao do material deve obedecer
Norma ISO 15156.
Caso no haja outra especificao explcita, a unidade de dessulfurizao deve ser projetada para
especificar o gs com teor mximo de 5 ppmv de H2S.
As seguintes diretrizes devem ser consideradas para seleo da tecnologia da Unidade de
Remoo de CO2 e H2S:
Para gs produzido com teor de CO2 menor ou igual a 10%, tecnologia por amina deve ser
utilizada para remover ambos os contaminantes ou apenas o H2S utilizando aminas
seletivas;
Para gs produzido com teor de CO2 maior que 10%, a tecnologia por membranas pode ser
utilizada para remoo do CO2, e o gs permeado com teor de CO2 enriquecido deve ser
reinjetado. Neste caso, as seguintes possibilidades devem ser avaliadas para remoo de
H2S:
Gs produzido com teor de H2S menor ou igual a 30 ppmv: a mesma unidade por
membranas deve ser preferivelmente utilizada para remover este contaminante em
conjunto com o CO2. Deve ser selecionado um destino adequado para o gs
permeado enriquecido em H2S (limitado a 200 ppmv), como, por exemplo, injeo
em poos;
Gs produzido com teor de H2S na faixa de 30 ppmv a 170 ppmv: tecnologia de
remoo de H2S por leito slido pode ser utilizada, a montante das membranas de
remoo de CO2;
Gs produzido com teor de H2S maior que 170 ppmv: a tecnologia de aminas deve
ser utilizada para remoo somente de H2S.
Para baixos teores de H2S, a injeo submarina de sequestrantes de H2S pode ser
economicamente vivel, e se indicada, deve ser requerida nas Bases de Projeto.
Tecnologias alm das diretrizes mencionadas neste documento podem ser avaliadas para cenrios
especficos.
Para sistemas usando membrana, uma linha de by-pass com uma vlvula de bloqueio mais uma
vlvula de controle de vazo deve ser utilizada, de forma a permitir desvio parcial e total do
sistema.
Para sistemas utilizando aminas, os seguintes requisitos devem ser atendidos:
Tanque de amina ou vasos com coneces para o vent atosfrico devem ser equipados
com nitrognio ou outro gs inerte para inertizao;
Instalaes para injeo de produtos qumicos (antiespumante) devem ser previstas;
Um pacote de filtrao contendo filtros de cartucho e carvo vegetal deve ser previsto para
remover impurezas oriundas da soluo de amina pobre;
Um vaso depurador deve ser previsto na entrada de gs do absorvedor, a fim de minimizar
o arraste de hidrocarbonetos pesados;
Um vaso depurador deve ser previsto na sada do absorvedor para prevenir a perda de
amina, com reciclo do lquido recuperado para o vaso surge;
No caso de sistemas de aquecimento de refervedor com resistncias eltricas, deve ser
utilizado um sistema de encamisamento, provido de resistncias de reserva, que permita a
troca de resistncias sem necessidade de drenagem do sistema de amina. O clculo da
carga trmica deve levar em considerao a perda de condutividade trmica provocada por
este encamisamento.
Um vent dedicado para a corrente gasosa proveniente da torre de regenerao de amina
deve ser previsto.
A eficincia do tratamento deve ser monitorada atravs da instalao de um analisador de
CO2 e/ou H2S online na sada da torre de contato, no mnimo, alm dos pontos de
amostragem para permitir anlises em laboratrio.
A corrente de gs com alta concentrao de H2S proveniente da unidade de regenerao
deve ser, preferivelmente, queimada;
Em caso de mau funcionamento da Unidade o gs fora de especificao deve ser
direcionado para a tocha (flare), atravs da vlvula de controle de presso do depurador de
produo.
O gs de baixa presso deve ser comprimido para uma presso tal que permita seu alinhamento
para o sistema principal de compresso de gs da plataforma. A presso de suco das Unidades
de Recuperao de Vapores (URVs) deve ser superior atmosfrica.
O escopo das URVs (pacote) no deve incluir ps-resfriadores (aftercoolers), j que sua descarga
ser misturada com o gs proveniente dos separadores, a montante do resfriador de gs (corrente
geral).
A vlvula de controle de presso que direciona o gs para a tocha de baixa presso deve ser
instalada a jusante do vaso depurador na suco do compressor. Em caso de parada do
compressor de recuperao de vapor, devem ser previstas instalaes de direcionamento de gs
para a tocha de baixa presso.
Os compressores de recuperao de vapor devem estar de acordo com o item 4.2.3.2 da DR-
ENGP-II-P1-2.1 Requisitos de Equipamentos Mecnicos.
A funo mais importante dos sistemas de descarte atmosfrico de hidrocarbonetos gasosos ser
um caminho (orifcio) aliviador de presso da planta de produo. Dispersar ou queimar
adequadamente o gs so funes fundamentais, porm secundrias primeira.
Os sistemas de descarte atmosfricos coadunam a escala de tempo dos eventos numa plataforma,
micro ou milisegundos, com a escala de tempo da reao humana por mais treinada que seja ou
esteja, minutos. Assim, os sistemas de descarte devem receber grandes variaes bruscas de
carga e trat-las adequadamente sem requerer interveno humana.
No projeto das linhas de gs para vent e tocha deve ser considerado fluxo no isotrmico a fim de
se avaliar a condensao nas linhas. O Projeto bsico deve considerar instalaes que previnem
contra presso e respingos de condensado na tocha ou no vent.
Todos os corta-chamas devem ser instalados em rea segura de acordo com API RP 14C e API
RP 2210. O projeto bsico deve definir o local apropriado garantindo a sua manuteno sem
parada de produo.
As Tabelas 1 e 2 a seguir, definem o tipo de sistema de descarte mnimo a ser utilizado em funo
das caractersticas de vazo/fluido descritas acima. Ao definir o sistema mnimo, isto significa que
pode ser utilizado qualquer sistema igual ou acima na classificao decrescente apresentada
acima.
Notas da Tabela 1:
(1) Esta tocha deve ser tanto quanto possvel estagiada de modo a que a vazo liberada para o meio
ambiente com velocidade menor que 150 m/s seja inferior a 3% da vazo mxima (capacidade) do sistema;
(2) Vent de Alta Velocidade (VAV) cuidadosamente projetado pode ser aceito;
(3) Tocha multiponto pode ser uma opo recomendada;
Notas da Tabela 2:
(1) Esta tocha deve ser tanto quanto possvel estagiada de modo a que a vazo liberada para o meio
ambiente com velocidade menor do que 150 m/s seja inferior a 3% da vazo mxima (capacidade) do
sistema;
(2) Tentar usar uma Tocha ou Tocha Multiponto como soluo ainda melhor para estas alternativas.
O sistema da tocha deve executar a combusto dos efluentes gasosos descartados pela UEP. A
combusto deve ser mantida estvel com ventos at 100 km/h mesmo nas baixas velocidades de
sada do gs.
O sistema de tocha deve queimar adequadamente qualquer vazo de gs desde a mnima at a
mxima, em qualquer condio de queima contnua e de emergncia. Os materiais do sistema de
tocha e das estruturas de suporte devem ser especificados para suportar vazo de gs de
emergncia no mnimo durante 24 horas. e vazo de gs contnua por um tempo indeterminado.
As situaes da UEP que devem ser consideradas como possveis causas da existncia de
condies de queima de emergncia so, no mnimo, as seguintes:
despressurizao;
falha e perda de ar de instrumentos;
incndio em algumas reas selecionadas;
erro de manobra;
parada do sistema de compresso.
Em projetos que utilizam compressores que despressurizam em parada normal, a tocha deve ter
capacidade para queimar a vazo de gs advinda da despressurizao dos compressores,
adicionada vazo que chega suco dos mesmos. Essa condio de queima ser classificada
como sendo de emergncia.
A seleo do tipo de tocha deve considerar os seguintes itens:
radiao trmica emitida;
qualidade de queima exigida;
comprimento das chamas;
presso disponvel;
turn-down mximo;
esforo de jato;
composio do gs a ser queimado;
nvel de rudo admissvel;
manuteno;
caractersticas de arranjo;
estrutura de suporte;
durao das campanhas entre paradas e
modo de troca da tocha (helicptero, guindaste ou tradicional).
Adicionalmente, prever linhas de despressurizao para a tocha, com controle manual, dos
gasodutos e dos anulares dos poos que operam com gas-lift. Esta despressurizao pode ser
utilizada somente aps a despressurizao da planta. O comprimento da estrutura de suporte e
outras dimenses do sistema de tocha no devem ser dimensionados com base nestas condies
de despressurizao.
A estrutura de suporte da tocha deve ser definida no Projeto Bsico, mas preferencialmente ser
do tipo torre.
No projeto trmico da tocha, para a aceitao do mximo fluxo de radiao total incidente sobre as
reas de trabalho, deve ser seguida a API-STD-521/ISO 23251. Nas condies contnuas, o fluxo
total mximo de radiao trmica incidente nas reas de trabalho da plataforma no pode ser maior
do que 1577 W/m2, sendo 789 W/m2 devido a tocha e 789 W/m2 devido ao sol. Nas condies de
emergncia, o fluxo total mximo de radiao trmica incidente nas reas de trabalho da
plataforma no pode ser maior do que 4737 W/m2, pelo perodo de 3 minutos, conforme
recomenda a API-STD-521/ISO 23251.
O fluxo mximo de radiao total incidente nas reas de trabalho deve ser calculado somando os
correspondentes fluxos mximos de radiao produzidos pelas condies contnuas e de
emergncia de alta e baixa presso.
O projeto trmico do sistema da tocha deve ser feito de modo a assegurar que os fluxos mximos
de radiao total incidente sobre as reas de trabalho atendam a estas diretrizes, sem o uso de
heat-shield, na plataforma.
A utilizao de heat-shield na estrutura de suporte da tocha deve ser minimizada e analisada em
cada projeto. O projeto trmico deve analisar a extenso e composio do heat-shield para
proteo trmica da estrutura da lana. A temperatura do ao da estrutura no deve ultrapassar
310C.
Deve ser considerado durante o projeto que o espao reservado para o gs deve ser adequado
para a reteno das gotculas maiores do que 300 micra, mesmo durante a ocorrncia do nvel
mximo de liquido.
Deve ser prevista instalao para esgotamento do vaso da tocha por gravidade, atravs de LV on-
off e em um tempo mximo de 5 minutos. O dimetro da linha de esgotamento deve ser no mnimo
3 pol., considerando que o lquido composto basicamente por condensado e leo na menor
seguintes tecnologias: radiao UV, radiao IR, ionizao de chama ou assinaturas acsticas da
chama.
13.2.9 Purga
Gs de purga deve ser injetado no sistema de tubulaes de gs para a tocha no(s) ponto(s) mais
a montante, ou seja, mais afastados da tocha de modo que todas as tubulaes permaneam
cheias de gs de purga e sob presso positiva.
Nos sistemas estagiados, deve ser previsto um ponto de purga com nitrognio a jusante de cada
uma das vlvulas dos estgios normalmente fechadas, de modo a manter um fluxo contnuo de gs
de purga at o topo da tocha.
A vazo de gs de purga deve ser de tal ordem a garantir uma velocidade mnima de 0,15 m/seg
nos orifcios de sada de gs para o meio ambiente. No trecho de tubulao com maior dimetro,
podem ser adotadas vazes de gs de purga menores, desde que atenda s exigncias da API
STD 521.
Devem ser previstas no mnimo duas fontes de gs de purga, com previso de medio de vazo,
alarme de vazo baixa e troca automtica entre fontes. A primeira fonte deve ser gs de boa
qualidade (gs combustvel), e a segunda deve ser de fonte de grande volume. O gs de purga
para a tocha deve ser monitorada por 3 (trs) transmissores de baixa vazo dispostos numa lgica
de votao 2 (dois) de 3 (trs) para iniciar um ESD-2.
O gs de purga deve ser realizado por gs natural, utilizando nitrognio como reserva, produzido
localmente a partir do ar atmosfrico e por uma unidade especfica e dedicada a essa funo
alimentada como carga essencial. O nitrognio gerado deve ter pureza superior a 96%.
No caso de uso de tocha de baixa velocidade (ponto nico), deve ser previsto o uso de selo
molecular ou fludico, para reduo do consumo de gs de purga.
As vlvulas de abertura rpida (QOV) devem ser instaladas no coletor principal da tocha a jusante
dos vasos knock-out de AP e BP. Cada QOV deve ter sua prpria proteo de Vlvula Buckling
Pin (BPV) em uma linha de desvio. A QOV e a BPV podem ser bloqueadas individualmente
somente para manuteno atravs de vlvula de esfera de abertura total. As vlvulas QOV devem
se mover de fechada para totalmente abertas em menos de 3 segundos.
O coletor da tocha de AP deve operar em uma faixa de presso definida pelo seguinte:
(i) o nvel de presso intermediria ajusta o alvio de sua taxa de vazo de gs para o coletor da
tocha de BP abrindo uma linha de comunicao entre os dois coletores de tocha;
(ii) o nvel de alta presso ajusta a abertura da QOV de AP para a Tocha de AP:
(iii) o nvel de baixa presso ajusta o fechamento da linha de comunicao entre os coletores de AP
e BP da tocha.
O coletor de baixa presso (LP) da tocha deve operar em uma faixa de presso definida pelo
seguinte:
(i) o nvel de presso intermediria ajusta a partida dos equipamentos de recuperao de presso
(compressor, edutor, soprador, etc.) que recupera o gs de BP do coletor da tocha de BP para a
entrada do sistema principal de compresso de gs;
(ii) o nvel de alta presso ajusta a abertura da QOV de BP para a Tocha de BP e o fechamento da
linha de comunicao entre os coletores das tochas de BP e AP;
(iii) o nvel de baixa presso ajusta a parada dos equipamentos de recuperao de presso.
Todos estes seis nveis de presso devem ser selecionados corretamente parra operao
apropriada e segura do sistema de Tocha Fechada.
Os coletores da tocha de AP e BP devem ser purgados com nitrognio de baixa pureza (96 a 98%)
gerado localmente a partir do ar atmosfrico atravs de pequenos geradores dedicados. Os
geradores de N2 devem ter arranjo de 2 x 100% e devem ser alimentados pelo circuito eltrico de
emergncia. Se os dois geradores de nitrognio falharem, uma linha dedicada de gs natural deve
alimentar gs de purga para o sistema. O sistema de purga deve ter medio de taxa de vazo
com alarme de baixa taxa de vazo e troca automtica de fonte de suprimento de gs de purga. O
gs de purga deve ser injetado nos coletores das tochas de BP e AP a jusante de suas vlvulas
QOV.
Sensores de oxignio devem ser instalados nos coletores das tochas de AP e BP a jusante de suas
vlvulas QOV. O nvel de oxignio dentro dos coletores de tocha deve ser mantido abaixo de 5%
em volume.
O gs de queima enviado para a tocha deve entrar em ignio logo ao chegar nos queimadores da
tocha. Dois sistemas de pilotos concomitantes devem ser instalados: (i) sistema de centelha
eltrica contnua e (ii) pelotas de ignio. O primeiro possui diversos dispositivos de ignio na
ponta da tocha (queimadores). O dispositivo de ignio pode operar continuamente ou ser partido
apenas quando a vlvula QOV abre. Entretanto, confiabilidade suficiente deve ser demonstrada na
partida da opo no contnua e resistncia suficiente deve ser demonstrada pela contnua. O
segundo baseado nas pelotas ou pequenos foguetes propelidos por ar comprimido. A pelota
enviada em alta velocidade atravs de um tubo de pequeno dimetro da plataforma at a ponta da
tocha onde atinge uma chapa de ao perto dos queimadores da tocha. Uma grande nuvem de
fascas provoca a ignio do gs da tocha. Deve haver um atraso entre a abertura da QOV
(fornecimento de gs de queima) e o despacho da pelota porque deve existir uma mistura de gs e
ar perto da ponta da tocha quando a pelota atinge a chapa de ao.
A prontido e disponibilidade do sistema de ignio deve ser monitorada continuamente e medidas
corretivas devem ser tomada imediatamente mesmo quando a tocha no estiver sendo usada.
Solues equivalentes para sistema de tocha fechada podem ser considerados. Entretanto, o
sistema de tocha fechada deve atender pelo menos as caractersticas descritas aqui.
O vaso depurador deve ser dimensionado com uma capacidade de acmulo de liquido (hold-up),
entre o nvel normal de liquido e o nvel mximo causador de parada de nvel 2 (ESD2), escolhido
como o maior valor estimado entre os seguintes casos:
Maior valor obtido por simulao;
Vazo de lquido correspondente a 5% da vazo mssica de gs em todas as condies de
queima.
Deve ser considerado durante o projeto que o espao reservado para o gs deve ser adequado
para a reteno das gotculas maiores do que 300 micra, mesmo durante a ocorrncia do nvel
mximo de liquido.
A rede de alvio e despressurizao deve atender aos mesmos critrios descritos no item 13.2.5.
O sistema deve ser estagiado para garantir que a velocidade sada dos gases seja sempre superior
velocidade mnima de 150 m/s. No ser necessrio atender ao critrio de velocidade mnima no
incio do 1 estgio (vazes menores do que 3% da capacidade do VAV).
O primeiro estgio no pode ser dimensionado com uma vazo mxima maior do que 10% da
vazo total do sistema de vent. O primeiro estgio deve ter corta-chama de meio de linha (flame
arrester) adequado para gs do grupo de exploso IIA (BS EN 12874:2001) com medio de
presso diferencial, monitorao da presena de chama (termopar) com acionamento automtico
do sistema de abafamento por CO2. O corta-chama deve ter seu interno (malha ou equivalente)
fabricado em ao inox 316 ou superior.
O sistema deve ter dois primeiros estgios idnticos e bloqueados por vlvulas intertravadas
mecanicamente de modo que seja possvel fazer manuteno e teste de entupimento (tomada de
injeo de N2 ou outro gs) do corta-chama do primeiro estgio que estiver fora de operao sem
retirar todo o sistema VAV de operao, o que obrigaria a parada da UEP.
O sistema de VAV deve ser protegido por sadas de segurana de igual capacidade ao sistema de
VAV, protegidas por vlvulas de pino de dobramento (buckling pin valves). Estas sadas de
segurana podem ser arranjadas de vrias maneiras: (i) uma vlvula de pino de dobramento por
vlvula on-off de comando de cada estgio, (ii) dois estgios de segurana com vlvulas de pino de
dobramento com 50% da capacidade do VAV cada um (VAV maiores do que 1.000.000 Nm3/dia)
ou (iii) ou apenas um estgio de segurana com vlvula de pino de dobramento com 100% da
capacidade do VAV (VAV menores do que 1.000.000 Nm3/dia).
As vlvulas de pino de dobramento devem ter suas presses de abertura escalonadas para evitar a
abertura simultnea de todas ao mesmo tempo. Recomenda-se que a presso de abertura das
vlvulas de pino de dobramento seja 50% superior maior presso de operao das vlvulas on-
off dos estgios. Deve-se observar que a presso de projeto mecnico do vaso do depurador do
vent deve ser maior do que o somatrio da (i) mxima perda de carga entre o vaso depurador do
vent e o VAV e (ii) presso de abertura das vlvulas de pino de dobramento do VAV.
A distncia entre o corta-chama e o orifcio de sada do gs no pode ser maior do que a distncia
para o qual o corta-chama foi testado e certificado. No utilizar corta-chamas do tipo final de linha e
com tampa.
A localizao final dos orifcios de sada do primeiro estgio deve garantir que a vazo do primeiro
estgio a 150 m/s ser adequadamente dispersa e no promova uma radiao, caso seja ativada,
maior do que 2650 W/m2 sobre as reas de trabalho.
As vlvulas liga-desliga de comando dos estgios devem ser do tipo falha fechada. Devem ser
previstas instalaes para testes de estanqueidade das vlvulas liga-desliga para comando dos
estgios: uma tomada para injeo de N2 entre as vlvulas de bloqueio dos estgios e as vlvulas
liga-desliga onde possa ser instalado um manmetro para verificao da eventual queda de
presso indicando vazamento. Devem ser executados testes peridicos de funcionamento do
sistema VAV.
A necessidade de gs de purga para o sistema de vent de alta velocidade deve ser definida pelo
Projeto Bsico.
13.3.3 Respiros
Os descartes devem ser instalados em locais elevados da UEP na direo dos ventos
predominantes.
Recomenda-se que os respiros sejam individualizados, ou seja, tanto quanto possvel ou razovel
cada respiro deve atender a um nico equipamento. O objetivo garantir a maior velocidade de
sada do gs para maximizar sua diluio com o ar e evitar a pressurizao de um equipamento
pela descarga de algum outro equipamento.
14. EXPORTAO DE GS
A capacidade de compresso deve atender a curva de injeo (vazo e presso) definida pelos
estudos de reservatrio.
O condensado eventualmente gerado na compresso deve ser movimentado em cascata para o
vaso depurador de nvel de presso imediatamente inferior. Ver o descrito para o sistema principal
de compresso.
Instalar vlvulas de reteno nas linhas dos anulares, entre a interligao do sistema de injeo e a
vlvula de bloqueio da linha de servio.
Equipar cada poo de injeo de gs e manifold de injeo com monitorao de presso e medio
de vazo.
Quando requerido pelo estudo de reservatrio, deve ser previsto um sistema de injeo de gua.
Este sistema deve ser dimensionado para atender curva prevista de injeo acrescida de 20%,
sem reserva.
O sistema de injeo de gua deve prever monitorao de corroso, conforme Captulo de
Monitoramento de Corroso (Captulo 21).
Filtros Grossos
Para a especificao da filtrao na captao de gua do mar, ver DR-ENGP-II-P1-1.2 Critrios
Gerais de Utilidades No-Eltricas.
A montante do primeiro equipamento do sistema de tratamento de gua de injeo (URS ou
desaeradora) deve ser instalado filtro autolimpante do tipo vela (candle), 25 micra, com
sobressalente a fim de permitir manuteno sem reduo de injeo de gua. A retrolavagem
deste filtro deve ser contnua, realizada com o mesmo em operao.
O elemento filtrante metlico deste filtro deve ser construdo com arame tipo wedge wire (arame
perfil trapezoidal). A taxa mxima de filtrao deve ser 8.300 m3/h/m2 (AAFT rea aberta filtrante
total). O material da carcaa e da tampa dos filtros deve ser ao carbono revestido e os internos
devem ser ao inoxidvel AISI 316L, AISI 321 ou superduplex.
Filtros finos
A especificao da qualidade da gua ser definida nas Bases de Projeto e deve estar de acordo
com o estabelecido na ltima reviso do Manual de Injeo de gua do E&P.
Para sistemas de injeo de gua sem URS, a filtragem fina deve ser composta de filtros cartuchos
com filtrao nominal e de profundidade, com reserva de forma a permitir a troca dos elementos
filtrantes sem reduo da injeo. Os elementos filtrantes devem ser em polipropileno, dimetro
externo de 2,5 pol, dimetro interno 1 pol e 60 pol de comprimento, sem emendas, com vazo de
gua de fora para dentro. A taxa de filtrao deve ser 4,2 m3/h/m2. O material da carcaa e da
tampa dos filtros deve ser ao carbono revestido e os internos devem ser de ao inoxidvel AISI
316L, AISI 321 ou superduplex. Os filtros devem ser dotados de sistema de fechamento/abertura
rpida.
Para sistemas de injeo de gua com URS, todos os filtros finos (injeo e sistema CIP da URS)
devem ser do tipo absoluto de modo a garantir o Silt Density Index (SDI) especificado pelo
fabricante da membrana. Os elementos filtrantes devem ser de polipropileno com dimetro de 6
pol, com 60 pol de altura, um anel O (O-ring) de vedao, com filtragem de dentro para fora (inside-
out). A taxa de filtrao deve ser 1.25 m3/h/m2. O material da carcaa e da tampa dos filtros deve
ser ao carbono revestido e os internos devem ser ao inoxidvel AISI 316L, AISI 321 ou
superduplex.
Para UEPs que requerem sistemas de gua de diluio com osmose reversa, os filtros finos devem
apresentar os mesmos requisitos dos filtros finos do sistema de gua com URS.
O sistema de fechamento dos filtros ser do tipo com abertura rpida.
A URS deve ter sistema dedicado de injeo de produtos qumicos fornecido junto com o Pacote.
A unidade deve considerar a utilizao de dois estgios, sendo o primeiro estgio dividido em dois
bancos. Deve ser considerada a configurao de trens 5x20%.
A figura 9 mostra o desenho esquemtico de um trem da URS.
A medio de vazo deve ser prevista na entrada e sada do permeado e rejeito de cada banco do
1o estgio e na sada do permeado e rejeito do 2o estgio.
Utilizar PSVs ao invs de discos de ruptura nas linhas de permeado.
O material do sistema de injeo do biocida DBNPA deve ser de material no metlico.
O analisador redox deve ser duplicado, com intertravamento lgico 1 de 2 e as dosagens de anti-
incrustrante e sequestrante de cloro devem estar intertravadas com a URS. Alm dos medidores de
vazo, esses instrumentos devem possuir by-pass para permitir a manuteno.
Sistema de Limpeza
Deve ser previsto um tanque de estocagem de gua doce ausente de cloro dedicado somente para
limpeza da URS e das turbinas. Este tanque deve ter flexibilidade para ser abastecido pela unidade
de gerao de gua doce bem como pelo rebocador. Deve ser considerado no clculo da
capacidade do tanque 1 m para cada 100 m3/d de permeado da URS.
Devem ser dimensionados 2 tanques para limpeza. Cada tanque de limpeza deve ser projetado
para um trem e dimensionado considerando um volume necessrio de 0,125 m por membrana. O
sistema de limpeza deve possuir flexibilidade de alinhamento para limpeza de um trem, um estgio
ou um banco.
Devem ser projetadas duas bombas de limpeza com configurao 2 x 100%, permitindo limpeza de
qualquer trem por qualquer bomba. Os filtros de limpeza devem ter configurao de 1 x 100% e
apresentar os mesmos requisitos dos filtros finos do sistema de gua do mar para injeo.
A medio da vazo de limpeza deve ser feita na suco das bombas.
A capacidade das bombas de limpeza deve ser de no mximo 10 vezes o nmero de vasos de
cada trem (ex.: um trem com 60 vasos, a vazo ser de 600m3/h por cada bomba) com operao
na faixa de 750 a 1000 kPa. O sistema de limpeza deve possuir uma linha de recirculao
posicionada a jusante da bomba de limpeza direcionada de volta ao tanque e isolada da linha de
descarte.
O alinhamento do sistema de limpeza deve ser por meio de vlvulas, no permitido o uso de
conexo manual do tipo Swing elbow - pescoos de ganso.
O sistema de limpeza deve ser projetado somente para uso de produtos lquidos com tubulao
dedicada ao abastecimento do tanque de limpeza.
A linha de gua doce do sistema de limpeza de membranas deve ser em material inerte
A parte superior do tanque de limpeza deve estar em rea livre descoberta.
A drenagem de todo o sistema da URS deve ser direcionada para a tubulao do sistema de
drenagem aberta no classificada da plataforma.
Torre Desaeradora
O sistema de desaerao fsica deve ser projetado para um teor mximo de O2 a 50 ppb.
O sistema de desaerao qumica deve ser projetado para um teor mximo de O2 a 10 ppb.
A torre desaeradora deve ser revestida internamente com material no metlico, para combater o
efeito de corroso.
O tipo de desaeradora deve ser definido pelas Bases de Projeto.
Sistema de Bombeio
O sistema de bombeio deve ser dimensionado para atender curva prevista de injeo acrescida
de 20%, sem reserva.
A vazo mnima destas bombas deve ser enviado para o sistema de descarga no mar.
A reinjeo de gua produzida tem por objetivo o descarte desta gua em reservatrios, visando
sua armazenagem geolgica ou recuperao secundria de petrleo.
O sistema de reinjeo de gua produzida deve ser instalado a jusante do sistema de tratamento
de gua oleosa, e deve constar dos seguintes equipamentos, quando aplicveis:
Sistema de filtrao;
Sistema de bombeio.
Esse sistema deve ser projetado para atender a especificao de qualidade de gua do campo,
fornecida pela Gerencia de Reservatrios do Ativo do campo onde a UEP ser instalada.
Deve ser prevista a instalao de sistema de monitorao da corroso conforme o captulo
Monitorao da Corroso (captulo 21).
No utilizar filtros de cartucho com limpeza cida.
No caso de utilizao de sistema de filtrao com retrolavagem (leito misto ou casca de noz), um
sistema adicional deve ser fornecido para garantir a retrolvagem, e deve ser definido no Projeto
Bsico.
Esta seo descreve os casos quando deve ser instalado um sistema de medio de vazo. No
caso de tais pontos serem previstos na medio de transferncia de custdia, pontos duplicados
no sero permitidos.
O sistema de medio deve estar conforme a DR-ENGP-I-1.6 Diretrizes para Sistemas de
Medio de leo e Gs Natural.
17.1.3 Medidor de Gs
Fornecer potes de selagem para os gases corrosivos.
Preferencialmente deve ser usado medidores ultrassnicos em linhas com dimetro maior que 6
polegadas. Estes medidores devem ser projetados, fabricados e instalados de acorodo com as
recomendaes da ltima reviso da norma AGA-9 e com as devidas calibraes e certificaes do
fabricante.
Adicionar os seguintes itens como notas no fluxograma de engenharia (P&ID):
Dar preferncia aos medidores em gs na posio horizontal, com a seo de medio
suficientemente apoiada para evitar vibraes.
No instalar o medidor em locais horizontais no nivelados.
Instalar o medidor em um local com fcil acesso para inspeo, reparo, manuseio e
calibrao.
Observar as distncias mnimas para a seo reta, a jusante e a montante de cada tipo de
medidor, ou uso de um retificador de vazo, instalado entre flanges.
As Bases de Projeto devem prever detalhes a respeito dos pontos de amostragem de acordo com
o P&ID-Notas Gerais emitido no ltimo projeto.
Para cada ponto de amostragem, os seguintes itens devem ser includos como notas no P&ID:
17.2.1.3 Amostragem de Gs
As vlvulas de amostragem devem ser localizadas na parte superior das linhas, quando instaladas
nas sees horizontais. Instalar as vlvulas nos seguintes pontos:
Na linha de sada de gs de cada vaso de produo e separador de teste;
A montante do sistema de compresso, a jusante dos vasos depuradores;
A jusante do depurador para cada estgio de compresso;
A jusante da unidade de desidratao de gs, antes do ponto de injeo (ponto para injeo
de produtos qumicos);
No sistema de gs combustvel, a jusante do vaso depurador;
Nas linhas de importao de gs de outras plataformas;
A montante do compressor de recuperao de vapor;
A montante e a jusante da unidade de remoo de CO2 e/ou H2S.
O material de construo da vlvula deve ser o mesmo da tubulao de gua para a primeira
vlvula de bloqueio e ao inox 316L a partir de ento.
Instalar o medidor de potencial de REDOX no mesmo ponto de amostragem (a montante do
desaerador). Instalar o medidor/ transmissor de oxignio dissolvido a jusante das bombas de
injeo principal, perto dos pontos de monitoramento de corroso. Instalar o analisador contador de
partcula a jusante das bombas de injeo principal.
17.2.2.1 Amostragem de Gs
Refere ao item 17.2.1.3
18.2 Inventrio
18.3 Arranjo
A rea de lay-down deve ter espao livre para tanques ou barris para 7 dias adicionais de
consumo.
O arranjo deve incluir estruturas para enchimento de tanques, que deve ser por gravidade sempre
que possvel, e usando container reutilizvel.
Instalar a unidade hidrulica perto da unidade de produtos qumicos, para evitar reas de
armazenamento separadas.
Localizar o armazenamento de produtos txicos e inflamveis em uma rea de processo, de modo
que este armazenamento no afete a classificao das outras reas.
Os tanques de produtos qumicos e suas linhas devem ser em fibra de vidro, sempre que possvel.
No caso de um produto inflamvel, no utilizar tanques de fibra de vidro. Instalar os tanques em
reas naturalmente ventiladas e equipar os tanques com vents individuais de ar. Os tanques para
produtos inflamveis devem ter corta-chamas e descarga de CO2.
18.4 Tanques
Cada tanque deve ser fornecido com uma linha de alimentao independente de 2 polegadas de
dimetro, com tela com malha 10 mesh, para evitar contaminao do produto, No utilizar
manifolds de suprimento.
Os tanques para produtos qumicos devem ter as seguintes caractersticas:
Fundo cnico, para facilitar a limpeza;
Bacias de conteno;
Boca de visita para permitir inspeo e limpeza interna;
Medidor de nvel de lquido. Fornecer monitoramento remoto do nvel de tanques para
plataformas no tripuladas;
Fcil acesso aos instrumentos e vlvulas;
Alarme de nvel alto;
Alarme de nvel baixo;
Vlvula de amostragem de tanque (pode ser na descarga da bomba).
As tabelas apresentadas nos itens 19.1, 19.2, 19.3, e 19.4 mostram as dosagens de produtos
prontos para uso, sem necessidade de diluio. feita exceo no caso do desemulsificante
invertido (polieletrlito) e inibidor de corroso em linha de gs (pontos de injeo diferentes
daqueles da exportao de gs).
18.5.2 Desemulsificante
O desemulsificante deve ser continuamente injetado:
Perto das ANSs (rvores de natal seca), a jusante do ponto de amostragem de lquido no
tubo ou ANMs usando linhas umbilicais de produtos qumicos.
Nos coletores de produo e teste, a jusante do ponto de amostragem de lquido.
Fornecer um ponto de espera na linha de gas-lift de cada poo, com vlvula de bloqueio, no caso
de ser detectado que a injeo atravs de tal linha mais eficiente do que a injeo nas ANMs. A
injeo simultnea na ANM e no gas-lift no ser permitida.
Nota: Poos equipados com BCSs devem ter injeo de desemulsificante e/ou anti-incrustante, se
necessrio, a montante da bomba. Somente produtos qumicos compatveis devem ser injetados
no mesmo ponto.
Prover instalaes para injeo de desemulsificante ou anti-incrustante na ANM usando linhas
umbilicais Produtos injetados a montante da BCSs no precisam ser injetados na ANM.
Os pontos de injeo do desemulsificante e do anti-incrustante devem estar localizados a mais
longe possvel um do outro, com mnimo de 2 metros, devido a incompatibilidade entre eles.
18.5.6 Xileno
O uso de xileno ser feito atravs de barcos de servio e no ser necessrio armazenamento.A
taxa de injeo ser definida na fase de projeto de detalhamento.
Para projetar esta unidade deve ser considerado que a temperatura de formao de hidrato ser,
no mnimo, mantida 5C abaixo da temperatura da corrente. Uma margem de segurana de 15%
deve ser considerada.
Todos os pontos de injeo devem usar bocais aspersores para distribuio do produto qumico.
Considerar os seguintes valores para calcular o sistema de produto qumico:
TOXIDAD CORROSIVIDAD
PRODUTO DOSAGEM (ppm) INFLAMABILIDADE
E E
1 a 15 L/h por poo na
Inibidor de hidrato sim sim sim
linha de gas lift;
Inibidor de corroso
1L/106 scf gs sim sim sim
por gs
Sequestrante de 25 L/kg H2S sim sim sim
Gasoduto de exportao;
Sistema de gs lift;
A jusante dos compressores de injeo de gs;
A montante da vlvula de controle de presso de gs combustvel;
Na sada de condensado do vaso de gs combustvel de alta presso.
Inibidor de hidrato deve ser injetado na linha de gs lift, individualmente por poo, e
independentemente da injeo no gasoduto de exportao usando bocal aspersor.
Para projetar esta unidade deve ser considerado que a temperatura de formao de hidrato ser,
no mnimo, mantida 5C abaixo da temperatura da corrente. Uma margem de segurana de 15%
deve ser considerada.
A taxa mnima de injeo para cada ponto deve ser de 1 (um) Litro/h.
A montante da desaeradora;
A jusante da desaeradora, no vaso de gua desaerada;
A jusante da URS.
Usando o sistema individual de dosagem, apenas um dos pontos deve ser usado por vez.
Nota: Para FPSO, o ponto de injeo a jusante da URS deve usar THPS ao invs de DBNPA como
biocida de choque.
Fornecer ponto de injeo de inibidor de incrustao a jusante da desaeradora, usando um sistema
de dosagem individual.
Biocida de choque (THPS para FPSOs e DBNPA para outras UEPs) deve ser injetado nos
seguintes pontos:
A montante da desaeradora;
A jusante da desaeradora;
No caso de uso de sistema de dosagem individual, somente um dos pontos ser usado de cada
vez.
Biodispersante deve ser injetado a jusante da desaeradora usando sistema de dosagem individual.
O sequestrante de cloreto da URS, o Anti-incrustante e o biocida da URS devem ser injetados a
montante da URS, usando sistema de dosagem individual.
18.8.3 Biocida
Biocida de choque e esttico devem ser injetados na linha de entrada do tanque de lavagem. Os
pontos de injeo devem ser instalados o mais prximo possvel na linha de sada de lquido do 2
estgio de gaseificao.
Em unidades usando tanques de gua produzida e tanques de slops, prover instalaes pra
injeo de biocida de choque e esttico. Ambos os produtos qumicos devem ser injetados
diretamente na fase aquosa desses tanques.
Oleodutos, gasodutos, dutos de gua e dutos multifsicos de exportao esto includos neste
item.
O projeto do lanador e recebedor de pig deve atender as especificaes padro.
Um lanador-recebedor pode ser usado para os dutos operando em duas direes (equipamento
de funo dupla).
Fornecer cmaras de lanamento/recepo de pig com facilidades para despressurizao,
interconectados ao sistema de tocha (baixa e alta presso) e sistema de vent.
Para gasodutos que no permitem a transferncia de lquido para os gasodutos subseqentes,
considerar a possibilidade de usar um coletor de condensado para receber os lquidos dos
escoamentos originados na passagem do pig de limpeza. No caso de no haver previso de
formao de lquido, o escoamento pode ser direcionado para o separador de teste durante as
fases de comissionamento e partida do gasoduto.
Fornecer todos os dutos com facilidades para o lanamento e recebimento pelo menos de pig tipo
espuma de baixa densidade, exceto os direcionados para monobias. Para os dutos que usam
apenas pig do tipo de espuma, o dimetro interno no deve ser menor do que 40% do maior
dimetro interno. (espaar) A recomendao que todos os oleodutos multifsicos e monofsicos
permitam a passagem pelo menos do pig do tipo convencional (pig rgido para limpeza).
As linhas sujeitas passagem de pig convencional devem atender s tolerncias da tabela abaixo:
Dimetro nominal do Pig Dimetro interno do tubo (polegada)
(polegada) Mnimo Mximo
4 3 4 3/16
6 5 6
8 7 8 3/16
10 9 10
12 11 12
14 13 13
Em todos os casos acima mencionados (pig de espuma e rgido), as transies de dimetro interno
devem ser chanfradas com inclinao mxima de 1:4 (30).
Para tubos com dimetros maiores ou iguais a 16, fornecer equipamentos de manuseio de
materiais para facilitar as operaes com pig convencional.
19.2.4 Gasodutos
Todos os gasodutos devem permitir a passagem de pig instrumentado exceto os 100% flexveis.
Todos os gasodutos com uma seo terrestre devem permitir obrigatoriamente permitir a
passagem de pig instrumentado.
Todos os gasodutos de exportao com presso operacional acima de 50 kg/cm2, interconectados
entre duas UEPs, sem conexo submarina com outros ramais, devem permitir a passagem de pig
instrumentado. No caso de arranjos submarinos com linha tronco e ramais operando acima de 50
kgf/cm2, a linha tronco deve permitir a passagem de pig instrumentado.
19.2.5 Excees
Sistemas de Produo Temporrios ou casos no cobertos nestas Diretrizes podem
ocasionalmente dispensar o uso de pig instrumentado com aprovao formal da Gerncia de
Inspeo de Dutos da Unidade de Negcios.
A variao do dimetro interno dos tubos deve ser compatvel com as tolerncias aceitveis.
Onde uma interconexo submarina for exigida para oleodutos e gasodutos e passagem de pig
instrumentado, usar uma conexo Y que acomode pig [PLEM]. No caso de dutos com dimetros
diferentes, localizados em uma profundidade de gua superior a 300 m, usar PLEMs equipados
com pig submarino.
No usar um T com grade em um PLEM para interligao de oleodutos com vazo convergente,
com um dimetro menor (ramal) posicionado na geratriz do duto superior. Usar o T com grade
somente na sada da rvore secundria com vazo divergente para a monobia operando com
petroleiro convencional, sem receptor de pig de espuma.
20.1 Geral
Soldar as conexes para acesso aos testadores de corroso na linha e fazer um furo atravs dos
mesmos com uma Mquina de Rosca a Quente (Hot Tape Machine), para permitir a manobra dos
dispositivos de monitoramento de corroso (cupons e sondas de corroso), sem
interferncia.Deixar somente os tampes nas conexes de acesso. Os dispositivos de
monitoramento de corroso somente devem ser instalados no momento da partida da operao da
UEP.
Separador de teste
Instalar uma conexo de acesso para a sonda de corroso com resistncia eltrica na
entrada de leo do separador de teste. Considerar sistema de monitoramento em linha, que
deve enviar um sinal para um sistema de aquisio, anlise e alarme instalado na sala de
controle da plataforma.
Compressores de gs
Instalar duas conexes de acesso na sada de gs de cada resfriador do pacote de
compresso, um para o cupom e outro para a sonda de corroso com resistncia eltrica.
Prever a interconexo futura de um sistema de monitoramento em linha para o sistema de
superviso.
Instalar duas conexes de acesso no coletor de descarga para os compressores, um por
cupom e outro para a sonda de corroso. Prever a futura interconexo de um sistema de
monitoramento em linha para o sistema de superviso.
Gasodutos
Instalar pelo menos duas conexes de acesso s linhas principais de exportao e
importao de gs (gasodutos), uma para o cupom de corroso e outra para a sonda de
corroso com resistncia eltrica, considerando sistema de monitoramento em linha para
enviar o sinal para o sistema de superviso. Instalar as conexes o mais longe possvel da
injeo de inibidor de corroso para permitir avaliar o desempenho do mesmo.
Oleodutos
Instalar pelo menos duas conexes de acesso s linhas principais de exportao e
importao de leo (oleoduto), uma para o cupom de corroso e outra para a sonda de
corroso com resistncia eltrica, considerando o sistema de monitoramento em linha para
enviar o sinal para o sistema de superviso. Localizar as conexes a jusante to longe
quanto possvel do ponto de injeo de inibidor, para permitir avaliao de desempenho do
mesmo.
Fornecer um dispositivo marinizado para medio de espessura por ultra-som nos risers de
oleoduto, incluindo na parte submersa, quando o estudo de corroso determinar a
existncia de fluidos substancialmente agressivos.