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Documento - Bases de Diseño
Documento - Bases de Diseño
Documento - Bases de Diseño
DESIGN BASIS
REPEXSA N°
INDEX
1. OBJECTIVE................................................................................................................................................................4
2. SCOPE.........................................................................................................................................................................4
3. REFERENCES............................................................................................................................................................4
4. DEFINITIONS AND ABBREVIATIONS.................................................................................................................5
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1. OBJECTIVE
The objective of this document is to set the basis of design to be used during the Detail engineering stage of the project.
This basis of design document shall be complete and clear enough to allow the performance of all required studies from
all the disciplines involved in.
2. SCOPE
Sagari Project new facilities and existing Kinteroni, intended to increase activities in this area due to natural gas
production at reservoir in Block 57 in Peru (Sagari AX and Sagari BX). The design basis is based on the Conceptual
Basis provided by Repsol and updated.
3. REFERENCES
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FO Optic Fiber
CP Cathodic Protection
Block 57 is located in the Ucayali and Madre de Dios Basins in the eastern Peruvian rainforest. This block is located
between the provinces of Satipo in the department of Junín, Atalaya in the department of Ucayali, and La Convención in
the department of Cusco. It is bordered by Block 90 to the north and Block 56 and 58 to the south, and is about 500 km
distance to the east of Lima city.
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Block 57 contains two gas and condensate discoveries (Kinteroni and Sagari) in the high-quality sandstones of Upper
NIA, Lower NIA, NOI and ENE.
Logistic base for development of Sagari project shall be located at Nuevo Mundo. This location is on the banks of
Urubamba River. Staff movement will be by plane to Nuevo Mundo and helicopter to Sagari and Kinteroni platform.
River transportation will be considered for load movement to Nuevo Mundo and transportation by helicopter to the
production platforms. As a restriction, it must be considered that Urubamba River has a navigable season from November
to March. Therefore, heavy loads have to be transported from November to March.
Sagari and Kinteroni platform shall be remote and unattended locations placed to the North West of Nuevo Mundo
station. There are neither roads nor rails close to these platforms. A severe constraint for this project is that, for
environmental reasons, facilities and ducts must use the minimum space possible.
Studies started in early 2008 for the development of Kinteroni project. One study was conducted to assess the feasibility
of different options for the development of Kinteroni and the use of Nuevo Mundo as an intermediate station. These
studies also were carried out to investigate those alternatives regarding the production and transportation scheme and to
determine the most suitable one.
In 2009-2010, the Conceptual Engineering and FEED were carried out for the development of Kinteroni project which
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The study for the first stage of compression at Nuevo Mundo station was conducted in 2012 with a Feasibility study and
the Conceptual Engineering. Finally, engine-driven reciprocating compression was the selected option. The Front End
Engineering Design for the first stage of compression was developed by Repsol Perú Business Unit together with
Pegasus. An update of the documents to reach 268 MMSCFD capacity of the plant has been developed by Repsol
Engineering Division in Madrid.
During 2013 a Visualization Study was carried out for the new Sagari AX/BX fields. Following the release of this
document a Conceptual Engineering Design has been performed to determine the final GTS selected alternative to
accomplish with the 268 MMSCFD capacity.
The goal of this document is to state the Basis of Design that will lead to the successful completion of the studies.
6. PRODUCTION PROFILES
Production profiles from both Sagari wells and the existing Kinteroni wells are shown in Appendix 2.
Plateau Rate is shown in Appendix 4 and Nuevo Mundo Suction Pressure in Appendix 5.
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7. DESIGN CASE
It will be considered one design case for the new surface facilities for a plateau of wet gas of 268 MMSCFD.
The lifetime of this project is 30 years.
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8. GAS FEED COMPOSITION
Gas composition for Sagari AX/BX and Kinteroni may be found in Appendix 1.
Environmental design criteria shall ensure that Sagari facilities meet Peruvian law, Repsol norms and those requirements
arising from EIA process.
The order of importance for codes and standards applicable to the Project will be:
• EIA requirements.
• Country or local’s statutory laws and regulatory requirements.
• Repsol norms (EPPs, EDs,etc).
The more stringent norms above mentioned will be taken as reference for this project when several of them
indicate different values for the same aspect.
See document SAG-TCH-GBL-H-PC-0012 “(CTR-807) Environmental and Safety Premises Review” for
detailed information about the environmental design criteria for the project.
As well as the document SAG-TCH-GBL-H-PC-0013 "(CTR-810) ESHIA and Environmental Statement
Review Report".
The environmental issue have been shown in the final EIA document reported to the Peruvian Authorities.
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Self-actuating shutdown valves shall be located at the inlet and outlet of Sagari AX platform and the
inlet of Kinteroni installation. These valves must have a bypass line for pressurization during start-up.
It is a valve arrangement with ball and globe valves sequentially installed.
o The valves are located at the Production Header inlet (see SAG-TCH-110-V-PID-0002 – P&ID
Pig Receiver Sagari AX), at the SA-KIN Flowline inlet (see SAG-TCH-110-V-PID-0003 – P&ID
Pig Launcher Sagari AX) and inlet in Kinteroni (see SAG-TCH-100-V-PID-0001 P&ID Pig
Receiver Kinteroni)
Self-actuating block valves shall have pressure regulators, air filters, air filter regulator, air accelerator,
intrinsically safe position indicators (open/closed), local control panel (with local trip and local partial
stroke) and solenoid valves. These valves must close at a minimum differential pressure drop per time
of 45 psi/min.
Possible erosion by condensate droplets and/or solids (sand) must be considered for the specification
of internal materials of regulating valves.
Any automatic valve furnished with pneumatic actuators must always turn into fail safe mode in case
of an air shortage or power outage, unless another action was specified.
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11.3 HIPPS
The purpose of the HIPPS system is to ensure a safe operation while avoiding the installation of a relief system in Sagari
AX/BX.
Overpressure protection system shall consist of shutting off the gas-condensate flow onto the
production cluster. HIPPS valves shall close the high pressure source before the operating pressure
reaches the design pressure thus avoiding system loss of containment and avoiding the use of flares
and safety relief devices.
For fire case, thermal switches will be installed to activate emergency isolation for closing the wells.
It has been agreed with Peru Business Unit to use the following criteria for the design of the system at shut off
conditions.
Table 2. Design Criteria at Shut off Conditions
HIPPS set pressure (psig) Wellhead design (psig) Christmas Tree design (psig)
Possible erosion by condensate droplets and/or solids (sand) must be considered for the specification
of internal materials of regulating valves.
Any automatic valve furnished with pneumatic actuators must always turn into fail safe mode in case
of an air shortage or power outage, unless another action was specified.
A multiphase flow metering unit is to be considered at the outlet of each well due to the limitations to install a
conventional test separator which would require an overpressure protection system.
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Multiphase flow meters are to be installed per well and mounted on its production pipeline. In the
Warehouse (at Nuevo Mundo location) one spare multiphase flow meter shall be available.
13.1 GENERAL
Design considerations shall consider that Sagari wells will be remote operated and the access will be by helicopter during
both construction and operation life of the wells.
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Diesel generator, chemical injection, instrument air, WHCP packages and Knock Out drum and reinjection Pumps shall
be sheltered.
The existing services and utilities in Kinteroni and Nuevo Mundo are appropriate for the operation of Sagari production,
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some modifications and new installation will be implemented in order to carry out the new production of Sagari. Please
refer to Item 14 of this document.
A cluster-type design shall be used: each well will connect to only one production manifold per
platform. Gas-condensates shall be transported through a multiphase pipeline to Nuevo Mundo
(depending on transport alternative) to be compressed and boosted to Malvinas Plant.
The above mentioned facilities must be designed for a safe operation. They will have to be distributed
in a minimum footprint in order to avoid further deforestation in the surrounding Amazon jungle.
Additionally, every reasonable effort shall be made to reduce power consumption in the production
platforms.
The production platforms shall be remotely controlled, monitored and operated from Nuevo Mundo
control room (at Unit 300).
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0 In the Heliport area, all channels are excavated in soil coated with HDPE geomembrane.The system includes new and
existing channels.
All the drainage in this area is sending to a chamber which has a valve outlet, and the drains are delivering to the ground
(rain water). During a discharge operation this valve shall be closed and just in case some spill goes to the chamber the
0
drains shall be collected by a flight pump (in the warehouse) to a drain drum.
The rain water collected by these channels, for both internal and external drainage system in operation platform, and in
heliport area, shall pass through the skimmers located in the facilities before being discharged to the ground.
For more details about the Drain System please refers to Drain System Philosophy SAG-TCH-V-FI-0003 and the
0 EARTHWORKS AND OPEN DRAINAGE document SAG-TCH-GBL-C-ES-5005 where the open drain was explained.
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corrosion inhibitor must be provided. Becorin corrosion inhibitor was defined during FEED Phase I for Repsol.
A discontinuous injection system of hydrate formation inhibitor is required to avoid the formation of solid compounds
and gas hydrates during start-up/shut-down operations, and gas cooling taking place on transport to Nuevo Mundo and
Malvinas Plant. To this end, Methanol was selected as a hydrate formation inhibitor.
According to Becorin provider recommendation the injection of corrosion inhibitor at Sagari AX and BX will be similar
as Kinteroni Facilities.
0
For Methanol injection a Dynamic Study has been taken place during Phase II, the following flow rates have been
defined for each well pad.
Sagari AX:
- Corrosion Inhibitor (Continuous) BECORIN: 0.82 BPD
- Hydrate Supresor (Discontinuous) Methanol: 120 BPD
- Becorin Drum: 23,8 BBL
- Methanol Drum: 14,3 BBL
0
Sagari BX:
- Corrosion Inhibitor (Continuous) BECORIN: 0.82 BPD
- Hydrate Supresor (Discontinuous) Methanol: 192 BPD
- Becorin Drum: 23,8 BBL
- Methanol Drum: 52 BBL
0
The scaling Index provides information about the possibility of a scale to form; the Scaling Index has been calculated
considering both Sagari and Kinteroni fields at nominal production rate.
According to the results obtained for Dynamic Study during FEED Phase I, CaCO3 scaling has been predicted for the 8”
flowline in year 2029, when a wet gas rate in the order of 15 MMscf/day is delivered from Sagari-BX. CaCO3 scaling is
not an issue for both 14” and 16” flowlines.
Due to these results, a connection for a future scaling inhibitor is installed in each production manifold at Sagari AX and
BX.
The refilling of chemical drums shall be by gravity from Heliport area to drums. Both injection systems have a spare
pump.
According to the Methanol Study (by TEA) in Sagari AX three pumps will be in operation during schedule stop up to
year 2020. At this time an increase in capacity (pumps and tank) should be necessary due to the biggest amount of water
prediction.
According to the Methanol Study (by TEA) in Sagari BX at reduced rate for year 2029, it is necessary operate with two
0 pumps. From year 2020 to 2029 it is necessary to increase the capacity (pumps and tank) in order to manage an
0 scheduled shut down.
Due to the bigger capacity of Methanol drum at Sagari BX (52 BBL) than AX (14,3 BBL), it is necessary to install two
drums each one with 26 BBL.
13.7 FLOWLINES
Flowlines will be designed by use of ASME B31.8 and API 5L codes with material type Gr70.
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Thickness, however, will be verified with ISO 13623. The most stringent result will be used.
Sizing of the flowlines shall follow the following criteria:
Table 3. Criteria for Flowlines Sizing
Vc Erosional flow velocity (transport of multiphasic fluid): it is defined as the velocity that may cause erosion to
the pipe and post corrosion:
C
V e= 1
ρf 2
Where
Ve = erosional velocity, ft/s
ρf = fluid density, lb/ft3
C = constant.
API RP (Recommended Practice) 14E recommends C values lower than 100 for situations where erosion may be
under control, and a range of 150-200 for fluids solids free. The minimum velocity is set by composition and type of
fluid (solids content, paraffin’s content, etc).
For more details please refer to SAG-TCH-GBL-V-MC-0005 MECHANICAL DESIGN TECHNICAL NOTE –
WALL THICKNESS CALCULATION.
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0 All the buried pipes (flowline or pipes inside the Sagari´s facilities) have a cathodic protection system.
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LOCATION
Geo-reference (UTM)
K: N: 8´727,211.2 E: 691,684.10
Kinteroni (K)
NM: N: 8´723,350.06 E: 701. 885.87
Nuevo Mundo (NM)
PA: N:8´703.970 E: 728.740
Pagoreni A (PA)
MA: N: 8`690.719 E: 701, 885.37
Malvinas (MA)
Elevation (m) above sea level (masl) K: 406 / NM: 365 / PA: 401 / MA: 377
Average: 80%
Annual Average Precipitation: 2,845.9 mm, Monthly: 736 mm, for the Winter season (November to
The weather station at Nuevo Mundo is located March)
at the south-eastern area, and has a registry of
two (02) years (2002 to 2004), with an annual
average of 3,679.8 mm. Design Rainfall for drainage: 40 mm/h
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Reglamento Nacional de
Seismic Design: Code:
Edificaciones (RNE)
16. APPENDIX
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Notes:
(1) The nitrogen % mole fraction in this table was adjusted according to the PVT data provided (in the Basis of
Design the indicated nitrogen % mole fraction is 1,96).
Schlumberger Surface Samples are available for the described fields. This composition is a typical composition for the
wells and was being taken into account for the development of the detail Engineering Phase.
Due to the GOR varies according to the production profiles (see Appendix 2), the composition must modify accordingly.
201100008 Repsol
Kinteroni 2 Upper NIA PVT Report with CVD 08012011.pdf
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Note that all developed documents in the Conceptual Engineering Design did consider the specific composition for each
field as represented in the previous table.
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Next tables show the production profiles of Sagari and Kinteroni fields (REPSOL). Wellhead pressure profiles are also
shown in these tables.
During the FEED stage, REPSOL clarified that the column Gas Rate not includes the free water and add the Oil Rate
column.
0 These Tables shall be taken into consideration for developing the simulation report and the Material Balance, all the data
and documents shall be in accordance with them.
Sagari BX
Oil Rate Gas Rate Water Rate Liquid Rate Pressure Temperature
Date
01/03/2014
01/03/2015
No production
01/03/2016
01/03/2017
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*The information shown in this table refers to the inlet conditions at the 8’’ flowline SAGARI BX-SAGARI AX.
*Information provided by Peru Business Unit considering their validated most profitable production profile.
*Data 2032 onwards has been deleted. It is considered that a flow under 10MMSCFD creates operations instability.
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0
Sagari AX + Sagari BX
Oil Rate Gas Rate Water Rate Liquid Rate Pressure Temperature
Date
01/03/2014
01/03/2015
No production
01/03/2016
01/03/2017
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*The information shown in this table refers to the inlet conditions at the 14’’ flowline SAGARI AX- KINTERONI. It
refers to the total flow from SAGARI AX/BX.
*Information provided by Peru Business Unit considering their validated most profitable production profile.
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Oil Rate Gas Rate Water Rate Liquid Rate Pressure Temperature
Date
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*The information shown in this table refers to the inlet conditions at the 16’’ flowline KINTERONI- NUEVO MUNDO.
It refers to the total flow from SAGARI AX/BX and KINTERONI.
*Information provided by Peru Business Unit considering their validated most profitable production profile.
Nuevo Mundo
Oil Rate Gas Rate Water Rate Liquid Rate Pressure Temperature
Date
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*Information provided by Peru Business Unit considering their validated most profitable production profile.
*The information shown in this table refers to the arrival conditions at NUEVO MUNDO.
*The end of the first stage of compression will occur in 2028/2029 as per the previous data (740psig suction pressure).
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250
200
150
MMSCFD Dry Gas
100
50
0
Mar/14 Aug/19 Feb/25 Aug/30 Jan/36 Jul/41 Jan/47
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2000
1500
psig
1000
500
0
Mar/14 Aug/19 Feb/25 Aug/30 Jan/36 Jul/41 Jan/47
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Sagari Listado de
Puntos.xlsx
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