Basic Training Plant Design Simulation

Process Simulation and Flare Network For Oil & Gas

BASIC TRAINING PLANT DESIGN SIMULATION

(PROCESS SIMULATION AND FLARE NETWORK) FOR
OIL & GAS INDUSTRY
ENGINEERING ACADEMY

ORIGINATOR:
FREDY ARY SADEWA, ST

17 - 20 FEBRUARY 2024

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 Basic Training Plant Design Simulation
Process Simulation and Flare Network For Oil & Gas

About The Auhor

Fredy Ary Sadewa has educational background as bachelor degree of Chemical Engineering
from Universitas Pembangunan Nasional “Veteran” Yogyakarta. He started study in year 2014 and
graduate in year 2019 with total study period 4 year more than 3 month.
During college period, he take several option course Petroleum Technology, Gas Plan,
Enhanced Oil Recovery (EOR). Besides take several option course, he also following training about
software hysys in year 2016 and succeed to finish the final project and get a certificate.
In professional experience he was internship in Pertamina Refinery Unit VI Balongan, in
Indramayu West Java as a Process Engineer in year 2018. When he has been graduating, he work in
PT Encona Inti Industri, PT Tripanji Puring, PT Berca Engineering International and PT Tripatra
Engineers and Constructors as a Process Engineer. During work, he has been worked project like
PreFEED, FEED, EPC and Blanket Engineering Study with several client in Indonesian like, Shel
Indonesia, Total Energies, Trans Pacific Petrochemical Indotama (TPPI), Pertamina Hulu Rokan (PHR),
Pertamina Hulu Sanga Sanga (PHSS), Petronas Carigali Ketapang II LMTD (PCK2L), Pangkah Saka
Indonesia Limited (PSIL), Tropik Energi Pandan, Pertamina Refinery Unit VII Kasim, Pertamina Hulu
Energi Offshore North West Java (PHEONWJ) and Wika Bitumen.
As a Process Engineer he can manage several software like Hysys, Unisim, Chemcad, Pipesim,
Instrucals, Flare System Analyzer, Pipenet, Aspen EDR, and HTRI.
List of Training about Process Engineering Topics:
1. Simulation Software HYSYS
2. Piping and Instrumentaion Diagram (P&ID)
3. Pipesim
4. Flare System Analyzer
5. AutoCAD 2D

IF YOU WANT TO FURTHERMORE TRAINING ABOUT PROCESS ENGINEERING TOPICS, YOU CAN CONTACT ME IN:

Email : [email protected]

Linkedin : Fredy Ary Sadewa

QUOTE
“The more I learn, the more I earn”
“The more I have to return”
“Learn, Earn, Return”

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 Basic Training Plant Design Simulation
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HYSYS and FLARE SYSTEM ANALYZER SOFTWARE

Aspen HYSYS is the energy industry’s process simulation software that’s used by top oil and gas
producers, refineries and engineering companies for process optimization in design and operations.

Aspen Flare System Analyzer is Complete flare system design, rating, and debottlenecking with Aspen
Flare System Analyzer for optimal flare system analysis of projects.

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Table of Contents
1 INTRODUCTION ................................................................................................................... 6
2 FACILITIES DECRIPTION ........................................................................................................ 7
2.1 Wellhead ............................................................................................................... 7
2.2 Central Processing Plant ....................................................................................... 7
3 DESIGN BASIS ...................................................................................................................... 8
3.1 Scope of Simulation .............................................................................................. 8
3.2 Simulation Software .............................................................................................. 8
3.3 Simulation Unit ...................................................................................................... 8
3.4 Feed Composition (Dry Gas) ................................................................................. 9
3.5 Wells Stream Data .............................................................................................. 10
4 PRODUCT SPECIFICATION .................................................................................................. 10
4.1 Sales Gas Specification ...................................................................................... 10
4.2 Fuel Gas Consumption ....................................................................................... 10
5 STARTING PROCESS SIMULATION (HYSYS) .......................................................................... 11
5.1 Input Component ................................................................................................ 11
5.2 Fluid Packages ................................................................................................... 11
5.3 Feed Stream ....................................................................................................... 11
5.4 Choke Valve........................................................................................................ 11
5.5 Manifold .............................................................................................................. 12
5.6 Inlet Cooler (E-100) ............................................................................................. 13
5.7 Production Separator (V-100) ............................................................................. 14
5.8 1st and 2nd Stage Compression System ............................................................... 15
5.8.1 1st Stage Compressor Scrubber (V-101) ........................................................................ 16
5.8.2 1st Stage Compressor (K-101) ........................................................................................ 17
5.8.3 1st Stage Compressor Cooler (E-101) ............................................................................ 18
5.8.4 2nd Stage Compressor Scrubber (V-102) ........................................................................ 19
5.8.5 2nd Stage Compressor (K-102) ....................................................................................... 20
5.8.6 2nd Stage Compressor Cooler (E-102) ............................................................................ 22
5.9 Feed Gas Scrubber (V-103) ................................................................................ 23
5.10 TEG Contactor (T-104) ....................................................................................... 24
5.11 Gas / Gas Exchanger (E-105) ............................................................................. 27
5.12 Inlet Scrubber (V-106) ......................................................................................... 29
5.13 Turbo Expander (EX-106) ................................................................................... 30
5.14 Low Temperature Separator (V-107) ................................................................... 31
5.15 Recompressor (K-106) ........................................................................................ 32
5.16 3rd Stage Compression System ........................................................................... 33
5.16.1 3rd Stage Compressor Scrubber (V-108) ........................................................................ 33
5.16.2 3rd Stage Compressor (K-108) ........................................................................................ 35
5.16.3 3rd Stage Compressor Cooler (E-108) ............................................................................ 36
5.17 Condensate Flash Vessel (V-109)....................................................................... 37
5.18 VRU Scrubber (V-110) ........................................................................................ 38
5.19 VRU Compressor (K-110) ................................................................................... 39
5.20 VRU After Cooler (E-110).................................................................................... 41
5.21 Fuel Gas Scrubber (V-120) ................................................................................. 42
5.22 Fuel Gas Heater (E-120) ..................................................................................... 43
5.23 Seal Gas Scrubber (V-120) ................................................................................. 44

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5.24 Seal Gas Heater ................................................................................................. 45

5.25 Subsea Pipeline .................................................................................................. 46
5.26 Inlet Separator ORF (V-201) ............................................................................... 46
5.27 Sales Gas ........................................................................................................... 47
6 LINE SIZING CRITERIA......................................................................................................... 47
7 OIL MANAGER ................................................................................................................... 48
7.1 Light Component ................................................................................................. 48
7.2 Starting Oil manager ........................................................................................... 48
7.3 Input Assay Data ................................................................................................. 49
7.4 Bulk Properties.................................................................................................... 50
7.5 Distillation ........................................................................................................... 50
7.6 Light End............................................................................................................. 50
7.7 Molecular Weight Curve ...................................................................................... 51
7.8 Density Curve ..................................................................................................... 51
7.9 Viscosity Curve ................................................................................................... 51
8 PRESSURE SAFETY VALVE ................................................................................................... 52
8.1 PSV Sizing .......................................................................................................... 53
9 STARTING FLARE HYDRAULIC (ASPEN FLARE SYSTEM ANALYZER) ........................................ 57
9.1 Input Composition ............................................................................................... 57
9.2 PSV Design......................................................................................................... 58
9.3 Flare Network...................................................................................................... 59
9.4 Criteria Design Selection ..................................................................................... 59
9.5 Result and Evaluation ......................................................................................... 60

List of Tables
Table 1 DRY GAS Composition ....................................................................................................... 9
Table 2 Well Properties ................................................................................................................. 10
Table 4 Sales Gas Specification .................................................................................................... 10
Table 5 Line Sizing Criteria ............................................................................................................ 48
Table 7 Light Component .............................................................................................................. 48
Table 8 Bulk Properties ................................................................................................................. 50
Table 9 Distillation Assay Data ...................................................................................................... 50
Table 10 Light End Basis ................................................................................................................. 50
Table 11 Molecular Weight Curve ................................................................................................... 51
Table 12 Density Curve ................................................................................................................... 51
Table 13 Viscosity Dynamic Curve 1 ............................................................................................... 52
Table 14 Viscosity Dynamic Curve 2 ............................................................................................... 52

List of Figures
Figure 1 Location Map ....................................................................................................................... 6
Figure 2 Block Diagram ..................................................................................................................... 7
Figure 3 Taurus 70 Datasheet ......................................................................................................... 10
Figure 4 Subsea Pipeline Schematic ............................................................................................... 46

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1 INTRODUCTION
Some gas field located in offshore will be develop to produce gas and condensate.
Following with figure indicates location.

Figure 1 Location Map

The preferred development concept is a wellhead and connected to a Central Processing

Platform (CPP) which will serve as processing and compression facilities. Upon processing, the gas
and condensate will be exported using export pipeline to existing Onshore Receiving Facilities (ORF)
with distance 110 kilometer.

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2 FACILITIES DECRIPTION
This project aimed to monetize gas and associated condensate reserves in the appraised area.
The facility is comprises Wellhead and Central Processing Platform. Block Diagram of field can be seen
in this following figure.

Figure 2 Block Diagram

2.1 Wellhead
The wellhead Block Diagram is required to accommodate single completion wells comprising gas
and associated condensate. Each wellhead is provided with Subsurface Safety Valve (SCSSV), Surface
Safety Valve (SSV) and Wing Valve (WV). Each flowline is provided with a manual adjustable choke
valve. The produced gas from all wells are to control gas are combined in the production manifold.

2.2 Central Processing Plant

All production fluids from Wellhead are routed to Inlet Cooler (E-100) prior to Production Separator
(V-100). Inlet cooler is an air cooled type heat exchanger which is designed to reduce the well stream
temperature to 50oC.
The Production Separator (V-2050) is a horizontal three (3) phase’s separator designed to separate
gas, condensate and water. Gas outlet from Production Separator will be routed to 1 st Stage Gas
Compressor. The Compression System is required to ensure export gas pressure is adequate to deliver
gas to ORF and to ensure appropriate operating pressure for the TEG Gas Dehydration System and
Dew Point Control Unit. The compression system consists of 2 (two) x 100% trains with 3 (three) stages
compressors. Each train consists of Inlet Scrubber, Compressor and After Cooler. The feed gas of the
3rd Stage Compressor will be taken from outlet of Dew Point Control System while the feed gas of 1st
Stage Gas Compressor are taken from gas outlet of Production Separator. The produced gas from
Production Separator or 2nd Stage Gas Compressor will be routed to TEG Gas Dehydration System.
TEG Gas Dehydration System comprises Feed Gas Scrubber and TEG Contactor. In the TEG
Contactor, gas is contacted with Tri Ethylene Glycol (TEG) to remove its water content to produce dry
gas. The Dehydration System is designed to achieve gas with water content of less than 5 lb/Mmscf.
Dried gas from TEG Contactor is then routed to Dew Point Control System.
The Dew Point Control System is designed to remove heavy hydrocarbon components so that there
is no condensation of gas along the export gas pipeline. The Dew Point Control System will consist of

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Gas/Gas Exchanger, Inlet Scrubber, Turbo Expander/Recompressor Package, and Low Temperature
Separator. The condensate from Dew Point Control System will be combined with condensate from
Production Separator and Compressor Suction Scrubber. Some of the gas outlet of the Dew Point
Control System will be sent to fuel gas system.
Treated gas from Dew Point Control System will be routed to 3rd Stage Gas Compressor prior being
delivered to the ORF via 14” subsea export gas pipeline.
The produced condensate from Production Separator (V-100), Dew Point Control System and also
from Compressor Suction Scrubbers will be let down its pressure to the delivery pressure prior to
entering the Condensate Flash Vessel. The condensate will be storage and the produced gas from Flash
Condensate Vessel will be compressed in Vapor Recovery Unit (VRU) and routed to fuel gas system.
Produced Water Treatment System shall be provided in CPP for treating the produced water
separated in the Production Separator (V-100). The produced water system is designed to reduce oil
content in the produced water down prior being discharged to the sea.

3 DESIGN BASIS

3.1 Scope of Simulation

Wellhead, Central Processing Plant (CPP) and Onshore Receiving Facilities (ORF) process
simulation includes the following process unit:
 Wellhead
 Production Separation System
 Gas Compression System
 TEG Gas Dehydration System
 Dew Point Control System
 Condensate Flash Vessel
 Vapor Recovery Unit
 Fuel Gas System and Seal Gas System
 Pipeline
 Inlet Separator ORF

3.2 Simulation Software

The Aspentech Hysys Version 11 Process Simulation software has been utilized to generate the
Heat and Material Balance for all design cases and apply the Peng Robinson Equation of State.

3.3 Simulation Unit

Diameter : inch

Length : Meter

Mass Density : Kg/m3

Mass Flow : Kg/hr

Molar Flow : MMSCFD

Pipe Roughness : inch

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Pressure : Barg

Pressure Drop : Psi / bar

Temperature : OC

Water Content : Lb/MMSCF

3.4 Feed Composition (Dry Gas)

The compositions of DRY GAS wells from reservoir are given in the following Table.
Table 1 DRY GAS Composition

LIQ
DENSIT PC ACCENTRIC VC
NO COMPONENT MOLE NBP(OC) MW Y TC(OC)
(BARG) FACTOR (CM3/MOL)
(KG/M3
)

1. N2 0.0177

2. H2S 0.0001

3. CO2 0.0193

4. Methane 0.8203

5. Ethane 0.0507

6. Propane 0.0405 DEFAULT BY HYSYS

7. i-Butane 0.0134

8. n-Butane 0.0144

9. i-Pentane 0.0063

10. n-Pentane 0.0043

11. n-Hexane 0.0048

12. C7+ 0.0039 91.95 96.00 738.00 263.34 28.44 0.3370 475.55

13. C8+ 0.0025 116.75 107.00 765.00 284.89 26.41 0.3740 487.84

14. C9+ 0.0009 142.25 121.00 781.00 308.93 24.05 0.4210 529.18

15. C10+ 0.0005 168.85 134.00 792.00 329.37 22.28 0.4630 573.72

16. C11+ 0.0002 187.25 147.00 796.00 348.08 20.76 0.5010 627.06

17. C12+ 0.0001 208.35 161.00 810.00 367.84 19.56 0.5430 675.17

18. C13+ 0.0001 227.25 175.00 825.00 386.75 18.60 0.5840 724.05

19. C14+ 0.0000 246.45 190.00 836.00 405.77 17.70 0.6260 782.99

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3.5 Wells Stream Data

The well stream inputted in the simulation is shown in Table 2:
Table 2 Well Properties

WELLS FTHP TOTAL FLOWRATE

FTHT (OC)
NO (BARG) (MMSCFD)

1. 45 79 93.3

4 PRODUCT SPECIFICATION
4.1 Sales Gas Specification
Sales gas specification are tabulated in table 4:
Table 3 Sales Gas Specification

NO PARAMETER UNIT VALUE

1. Pressure Barg 35-40

2. Temperature OC 23-31

3. Molar Flow MMSCFD Minimum 80

4. Water Content Lb/MMSCF <2

5. CO2 Composition %mole <3

4.2 Fuel Gas Consumption

Fuel gas demand are refer to Taurus 70 for Gas Turbine Compressor, the specification is attach in
below:

Figure 3 Taurus 70 Datasheet

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5 STARTING PROCESS SIMULATION (HYSYS)

5.1 Input Component

Input component is the first step before simulation is start. Data from section 3.4 shall be input to
process simulation.
Click on the component list and select component in pure component.

5.2 Fluid Packages

Peng Robinson is applied for this simulation

5.3 Feed Stream

To starting process simulation in hysys worksheet, properties data (pressure, temperature and
flowrate) and composition shall be defined first.

5.4 Choke Valve

Choke valve is used for adjusting pressure or flowrate of fluid from wellhead flowline. In this
simulation choke valve assumed have pressure drop 10 psi.
For starting simulation of choke valve:
1. Select / search icon valve in pallete

2. Determined inlet and outlet of choke valve

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3. And the last, in parameter menu is determine input pressure drop of choke valve

5.5 Manifold
Manifold is gathering system of fluid from each wells or source before entering to pipeline,
trunkline or process in processing facility.
For starting simulation of manifold:
1. Select / search icon mixer in pallete

2. Determined inlet and outlet of manifold. Source / inlet of mixer can consist more than one /
several source or inlet. For outlet only one stream that can create as product.

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3. In parameter menu, select criteria of pressure assignment. For “equalize all” the inlet stream of
mixer will be create similar for each input and also of outlet. For “set outlet to lowest inlet” the
pressure outlet will be set based on lowest value of each source or inlet stream from manifold.

5.6 Inlet Cooler (E-100)

Inlet Cooler is used to reduce temperature before entering production separator and also reduce
temperature in discharge compressor cause differential pressure (compression). The pressure criteria
is 10 psi and outlet temperature is 50OC
For starting simulation of inlet cooler:
1. Select / search icon cooler in pallete

2. Determined energy, inlet and outlet stream of inlet cooler in menu connection. Energy is
indication that cooler is release of heat cause differential temperature in cooler.

3. Determined pressure drop of inlet cooler in parameter menu. For delta T and Duty will automatic
shown.

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4. In worksheet, determined outlet temperature of inlet cooler as 50OC

5.7 Production Separator (V-100)

Production separator (horizontal 3 phase separator type) is used to separate gas, liquid and water
phase. After fluid is separate, the fluid will be process accordance with requirement of fluid impurities or
depending of purpose. The pressure drop criteria is 0.3 bar
For starting simulation of inlet cooler:
1. Select / search icon 3 phase separator in pallete

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2. In connection menu shall determine of inlet and outlet 3 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas, liquid and water phase) and for “vapour outlet” the pressure
drop is only in outlet of gas phase.

5.8 1st and 2nd Stage Compression System

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5.8.1 1st Stage Compressor Scrubber (V-101)

1st stage compressor scrubber is used for separate of gas and mixed liquid phase (liquid and water)
and prevent liquid carry over before gas entering suction compressor. The type scrubber is 2 phase
vertical separator and have pressure drop 0.3 bar.
For starting simulation of 1st stage compressor scrubber:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

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3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.8.2 1st Stage Compressor (K-101)

1st stage compressor is used for compressed gas until reach pressure 50.45 barg.
For starting simulation of compressor:
1. Select / search icon compressor in pallete

2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

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3. In parameter menu shall determine of efficiency, polytropic method, operating method, curve
input option
- Efficiency
Compressor have two efficiency adiabatic and polytropic. Adiabatic is the ratio of work output
for an ideal isentropic compression process to the work input to develop the required head. For
polytropic is is the limiting value of the isentropic efficiency as the pressure increase approaches
zero, and the value of the polytropic efficiency is higher than the corresponding adiabatic
efficiency
- Operating method
Operating method is indicate type of compressor based on flowrate, type fluid and ratio or
discharge pressure.

5.8.3 1st Stage Compressor Cooler (E-101)

1st stage compressor after cooler is used for reducing temperature from discharge cooler until
reach suction compressor temperature (50OC) and reducing impurities (heavy fraction and CO2).
For starting simulation of air cooler:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet.

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3. In parameter menu, input air intake (pressure and temperature), configuration, air cooler model
and pressure drop is 10 psi. Select the air intake for pressure 0 barg and temperature 33 OC
- Air intake
Air intake is air that use for cooling process of fluid, the indicate is pressure and temperature.
- Configuration
Configuration is type / model of air cooler that consist of pass (bay) and tube.

5.8.4 2nd Stage Compressor Scrubber (V-102)

2nd stage compressor scrubber is used for separate of gas and mixed liquid phase (liquid and water)
and prevent liquid carry over before gas entering suction compressor. The type scrubber is 2 phase
vertical separator and have pressure drop 0.3 bar.
For starting simulation of 1st stage compressor scrubber:
1. Select / search icon separator in pallete

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2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.8.5 2nd Stage Compressor (K-102)

2nd stage compressor is used for compressed gas until reach pressure 60.00 barg.
For starting simulation of compressor:
1. Select / search icon compressor in pallete

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2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

3. In parameter menu shall determine of efficiency, polytropic method, operating method, curve
input option
- Efficiency
Compressor have two efficiency adiabatic and polytropic. Adiabatic is the ratio of work output
for an ideal isentropic compression process to the work input to develop the required head. For
polytropic is is the limiting value of the isentropic efficiency as the pressure increase approaches
zero, and the value of the polytropic efficiency is higher than the corresponding adiabatic
efficiency
- Operating method
Operating method is indicate type of compressor based on flowrate, type fluid and ratio or
discharge pressure.

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5.8.6 2nd Stage Compressor Cooler (E-102)

2nd stage compressor after cooler is used for reducing temperature from discharge cooler until
reach suction compressor temperature (50OC) and reducing impurities (heavy fraction and CO 2).
For starting simulation of air cooler:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet.

3. In parameter menu, input air intake (pressure and temperature), configuration, air cooler model
and pressure drop. Select the air intake for pressure 0 barg and temperature 33OC
- Air intake
Air intake is air that use for cooling process of fluid, the indicate is pressure and temperature.
- Configuration
Configuration is type / model of air cooler that consist of pass (bay) and tube.

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5.9 Feed Gas Scrubber (V-103)

Feed gas scrubber is used for separate of gas from mixed liquid phase and impurities (heavy
fraction and CO2) before gas entering TEG Contactor and ensure only single phase when inlet to TEG
Contactor.
For starting simulation of feed gas scrubber:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

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3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.10 TEG Contactor (T-104)

TEG Contactor is used for reducing water content from sales gas. Water raise quality of gas is
poor since containment is reducing heating value. The fluid that used for adsorb water is glycol, in this
simulation will using TE Glycol with purity (99% mole fraction) with requirement flowrate 10.000 kg/hr.
For starting simulation of TEG Contactor:
1. Select / search icon absorber in pallete

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2. In connection menu shall determine of inlet and outlet. Gas shall inlet from bottom and rich TEG
inlet from top of column. For outlet sales gas shall out from top and lean TEG will be out from
bottom of column. Then click on next menu. Total stage is 10.

3. Fill the pressure of top and bottom stage pressure. For top stage pressure is 58 barg and bottom
stage pressure is 59 barg. Then click on next menu.

4. Top stage temperature is optional for fill or not, for this simuation temperature is ignore or not
filled. And then click on done menu.

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5. Filling data will shown on simulation menu. And next is click on the run menu for change
uncorverged to converged that indicate simulation running.

6. After section 4.16 is done, stream from low temperature will connect to shell side gas / gas
exchanger.

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5.11 Gas / Gas Exchanger (E-105)

Gas / gas exchanger is used for heat integration of gas that will process in low temperature section
and gas that will sent to sales gas section and also reducing containment from gas.
For starting simulation of Gas/Gas Exchanger:
1. Select / search icon absorber in pallete

2. Determined stream inlet and outlet (shell and tube), since the fluid from Low Temperature
Separator (V-107) not yet known, shell side temporary not fill.

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3. In parameter menu, determined pressure drop of shell and tube (10 psi). For this simulation is
used 1 shell pass and 2 tube passes and counter current flow type.

4. Fill the temperature outlet of tube side gas / gas exchanger, assumed 30 OC ( this value will re
adjust after fluid from low temperature separator V-107 is known)

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5.12 Inlet Scrubber (V-106)

Inlet scrubber is used for separate of gas and mixed liquid phase and prevent liquid carry over
before gas entering expander. The type scrubber is 2 phase vertical separator and have pressure drop
0.3 bar.
For starting simulation of inlet scrubber:
1. Select / search icon separator in pallete

2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

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3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.13 Turbo Expander (EX-106)

Turbo expander is used for drop down temperature of sales gas at dew point. Since sales gas
temperature is drop until dew point, temperature operating will change to low operating temperature and
also with it pressure (JT Effect). For this simulation dew point is 8OC

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For starting simulation of turbo expander:
1. Select / search icon expander in pallete

2. In connection menu, select the inlet, outlet and also energy requirement. Turbo expander will
generate the power.

3. Then input dew point value of simulation 8OC in worksheet stream outlet or trial the pressure
until reach temperature 8OC.

5.14 Low Temperature Separator (V-107)

Low temperature separator (LTS) is used for separate gas and liquid as per result of JT effect
turbo expander,
For starting simulation of low temperature separator:
1. Select / search icon expander in pallete

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2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.15 Recompressor (K-106)

Recompressor is used for compress sales gas before entering 3rd stage compressor system and
split to fuel gas system. Recompressor is utilize power result from turbo expander for drive engine
compressor.

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For starting simulation of recompressor scrubber:
1. Select / search icon compressor in pallete

2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

3. With utilize power from turbo expander, recompressor will generate pressure.

5.16 3rd Stage Compression System

5.16.1 3rd Stage Compressor Scrubber (V-108)

3rd stage compressor scrubber is used for separate of gas and mixed liquid phase (liquid and water)
and prevent liquid carry over before gas entering suction compressor. The type scrubber is 2 phase
vertical separator and have pressure drop 0.3 bar.
For starting simulation of 3rd stage compressor scrubber:

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1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

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5.16.2 3rd Stage Compressor (K-108)

3rd stage compressor is used for compressed gas until reach pressure 70.00 barg to compress
sales gas reach onshore receiving facilities (ORF) via subsea pipeline.
For starting simulation of compressor:
1. Select / search icon compressor in pallete

2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

3. In parameter menu shall determine of efficiency, polytropic method, operating method, curve
input option
- Efficiency
Compressor have two efficiency adiabatic and polytropic. Adiabatic is the ratio of work output
for an ideal isentropic compression process to the work input to develop the required head. For
polytropic is is the limiting value of the isentropic efficiency as the pressure increase approaches
zero, and the value of the polytropic efficiency is higher than the corresponding adiabatic
efficiency
- Operating method
Operating method is indicate type of compressor based on flowrate, type fluid and ratio or
discharge pressure.

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5.16.3 3rd Stage Compressor Cooler (E-108)

3rd stage compressor after cooler is used for reducing temperature from discharge cooler until
reach suction compressor temperature (50OC) and reducing impurities (heavy fraction and CO 2).
For starting simulation of air cooler:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet.

3. In parameter menu, input air intake (pressure and temperature), configuration, air cooler model
and pressure drop. Select the air intake for pressure 0 barg and temperature 33 OC
- Air intake

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Air intake is air that use for cooling process of fluid, the indicate is pressure and temperature.
- Configuration
Configuration is type / model of air cooler that consist of pass (bay) and tube.

5.17 Condensate Flash Vessel (V-109)

Condensate flash vessel is collect condensate from separator or scrubber as result separation
process. Condensate flash vessel have operating pressure 11 barg to flashing condensate.
For starting simulation of condensate flash vessel:
1. Select / search icon separator in pallete

2. Change icon of the separator to horizontal type.

3. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

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4. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.18 VRU Scrubber (V-110)

VRU scrubber is used for separate of gas and liquid carry over from condensate flash vessel before
gas entering to suction compressor. The type scrubber is 2 phase vertical separator and have pressure
drop 0.3 bar.
For starting simulation of VRU scrubber:
1. Select / search icon separator in pallete

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2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.19 VRU Compressor (K-110)

VRU compressor is used for compressed gas until reach pressure 43.00 barg to compress gas for
requirement fuel gas system that will be tie-in with discharge from recompressor..
For starting simulation of compressor:
1. Select / search icon compressor in pallete

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2. In connection menu shall determine of energy, inlet and outlet. Energy is indication that
compressor need power from gas engine compressor.

3. In parameter menu shall determine of efficiency, polytropic method, operating method, curve
input option
- Efficiency
Compressor have two efficiency adiabatic and polytropic. Adiabatic is the ratio of work output
for an ideal isentropic compression process to the work input to develop the required head. For
polytropic is is the limiting value of the isentropic efficiency as the pressure increase approaches
zero, and the value of the polytropic efficiency is higher than the corresponding adiabatic
efficiency
- Operating method
Operating method is indicate type of compressor based on flowrate, type fluid and ratio or
discharge pressure.

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5.20 VRU After Cooler (E-110)

VRU after cooler is used for reducing temperature from discharge cooler until reach temperature
(50OC) before entering fuel gas system
For starting simulation of air cooler:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet.

3. In parameter menu, input air intake (pressure and temperature), configuration, air cooler model
and pressure drop. Select the air intake for pressure 0 barg and temperature 33 OC
- Air intake

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Air intake is air that use for cooling process of fluid, the indicate is pressure and temperature.
- Configuration
Configuration is type / model of air cooler that consist of pass (bay) and tube.

5.21 Fuel Gas Scrubber (V-120)

Fuel gas scrubber is used for separate gas and luqid phase before entering fuel gas user. Fuel
gas scrubber have operating pressure 38 barg and pressure drop 0.3 bar.
For starting simulation of fuel gas scrubber:
1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

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3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

5.22 Fuel Gas Heater (E-120)

Fuel gas heater is used to raise temperature before use as fuel gas user. The temperature is raise
until 75OC and pressure drop criteria is 10 psi.
For starting simulation of inlet cooler:
1. Select / search icon heaterr in pallete

2. Determined energy, inlet and outlet stream of fuel gas heater in menu connection. Energy is
indication that heater is required of heat cause differential raise temperature.

3. Determined pressure drop of inlet cooler in parameter menu. For delta T and Duty will automatic
shown.

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5.23 Seal Gas Scrubber (V-120)

Seal gas scrubber is used for separate gas and luqid phase before entering fuel gas user. Fuel
gas scrubber have operating pressure 1.25 pressure ratio of suction compressor and pressure drop 0.3
bar and flowrate is 2000 kg/hr.

For starting simulation of fuel gas scrubber:

1. Select / search icon separator in pallete

2. In connection menu shall determine of inlet and outlet 2 phase separator. Energy is not required
if the vessel not any differential temperature.

3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas and liquid phase) and for “vapour outlet” the pressure drop
is only in outlet of gas phase.

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5.24 Seal Gas Heater

Seal gas heater is used to raise temperature before use as fuel gas user. The pressure is raise
until 55OC and pressure drop criteria is 10 psi.
For starting simulation of inlet cooler:
1. Select / search icon heaterr in pallete

2. Determined energy, inlet and outlet stream of fuel gas heater in menu connection. Energy is
indication that heater is required of heat cause differential raise temperature.

3. Determined pressure drop of inlet cooler in parameter menu. For delta T and Duty will automatic
shown.

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5.25 Subsea Pipeline

Subsea pipeline is transport for sales gas from offshore central processing plant to onshore
receiving facility (ORF) with distance 110 km. incoming pipeline have operating temperature 300C.
The criteria of pipeline is:
Diameter : 14”
Roughness : 0.0018”
Material : carbon steel
Pipe wall conductivity : 45 W/m.K
The schematic of subsea pipeline shown in figure 5 :

Figure 4 Subsea Pipeline Schematic

5.26 Inlet Separator ORF (V-201)

Inlet separator (horizontal 3 phase separator type) is used to separate gas, liquid and water phase
from subsea pipeline transportation that higher lead pressure drop along pipe. The operating pressure
of inlet separator ORF is 40 barg and pressure drop criteria is 0.3 bar.
For starting simulation of inlet cooler:
1. Select / search icon 3 phase separator in pallete

2. In connection menu shall determine of inlet and outlet 3 phase separator. Energy is not required
if the vessel not any differential temperature.

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3. In parameter menu, input the pressure drop of separator. For “inlet” the pressure drop will be
calculate overall of each outlet (gas, liquid and water phase) and for “vapour outlet” the pressure
drop is only in outlet of gas phase.

5.27 Sales Gas

After gas outlet from inlet separator ORF, the gas will inlet to gas metering and then transport to
customer.

6 LINE SIZING CRITERIA

Refer to API 14E Standard (Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems), gas, liquid and multhiphase fluid have criteria sizing design. The
criteria of sizing is tabulated in table 5:

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Table 4 Line Sizing Criteria

MAX VELOCITY MIN VELOCITY

NO PHASE NOISE (DB)
(FT/S) (FT/S)

1. GAS 60 85

2. LIQUID 15 3

Below Erosional
3. MUTHIPHASE
Velocity

7 OIL MANAGER
Characterization of hydrocarbon fluids by determining the hypothetical components that make up
the oil and predicting the thermo physical and transport properties of petroleum. In general, oil manager
use in refinery or downstream sector. In refinery or downstream have complexity component and
system.
Oil manager data in general, obtained from sample analysis or licensor company. For this
simulation use Peng Robinson for fluid package.

7.1 Light Component

Light component is tabulated in table 7:
Table 5 Light Component

NO COMPONENT

1. H2O

2. Propane

3. i-Butane

4. n-Butane

5. i-Pentane

6. n-Pentane

7.2 Starting Oil manager

For staring oil manager is select on oil manager menu and then click on the menu input assay.
After it click on add menu to create new assay.

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7.3 Input Assay Data

 Bulk Properties : Bulk properties are the average properties of all the molecules in
collection. The most common properties of crude oil are density (API), viscosity and boiling
point range.
 Assay Data Type : Assay data type are type of analysis fluid sample that used for
simulation. For this simulation is using TBP (True Boiling Point) method.

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7.4 Bulk Properties

Bulk properties is tabulated in table 8:
Table 6 Bulk Properties

NO PARAMETER UNIT VALUE

1. Molecular Weight 300

2. Standard Density API_60 48.75

7.5 Distillation
Bulk properties is tabulated in table 9:
Table 7 Distillation Assay Data

NO ASSAY PERCENT (MOLE FRACTION) TEMPERATURE (OF)

1. 0 80

2. 10 255

3. 20 349

4. 30 430

5. 40 527

6. 50 635

7. 60 751

8. 70 915

9. 80 1095

10. 90 1277

11. 98 1410

7.6 Light End

Light end basis s is tabulated in table 10:
Table 8 Light End Basis

NO COMPONENT COMPOSITION (MOLE FRACTION)

1. H2O 0

2. Propane 0

3. i-Butane 0.19

4. n-Butane 0.11

5. i-Pentane 0.37

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NO COMPONENT COMPOSITION (MOLE FRACTION)

6. n-Pentane 0.46

7.7 Molecular Weight Curve

Molecular weight curve is tabulated in table 11:
Table 9 Molecular Weight Curve

NO ASSAY PERCENT (MOLE FRACTION) MOLECULAR WEIGHT

1. 0 68

2. 10 119

3. 20 150

4. 30 182

5. 40 225

6. 50 282

7. 60 350

8. 70 456

9. 80 585

10. 90 713

11. 98 838

7.8 Density Curve

Density curve is tabulated in table 12:
Table 10 Density Curve

NO ASSAY PERCENT DENSITY (API)

1. 13 63.28

2. 33 54.86

3. 57 45.91

4. 74 38.21

5. 91 26.01

7.9 Viscosity Curve

Viscosity curve is tabulated in table 13 and 14:

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Table 11 Viscosity Dynamic Curve 1

NO ASSAY PERCENT VISCOSITY (CP) TEMPERATURE (OF)

1. 10 0.2

2. 30 0.75

3. 50 4.2 100

4. 70 39

5. 90 600

Table 12 Viscosity Dynamic Curve 2

NO ASSAY PERCENT VISCOSITY (CP) TEMPERATURE (OF)

1. 10 0.1

2. 30 0.3

3. 50 0.8 100

4. 70 7.5

5. 90 122.3

After all was input, then click on calculate menu The assay will be automatic to calculate

After calculate, click on the output blend to input assay before starting simulation. Fluid properties
is already to analysis and simulation.

8 PRESSURE SAFETY VALVE

Pressure Safety Valve (PSV) is a pressure relief device designed to open and relieve excess
pressure and to reclose and prevent the further flow of fluid after normal conditions.

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Type of PSV :
 Conventional PSV : is a spring loaded pressure relief valve whose operational
characteristics are directly affected by changes in the back pressure. Maximum back
pressure is 10% of set pressure.
 Balance Below PSV : is a spring loaded pressure relief valve that incorporates a bellows
or other means for minimizing the effect of back pressure on the operational characteristics
of the valve. Maximum back pressure is 30% of set pressure.
 Pilot PSV : is a pressure relief valve in which the major relieving device or main
valve is combined with and controlled by a self actuated auxiliary pressure relief valve
(pilot). Maximum back pressure is 50% of set pressure.

8.1 PSV Sizing

 Click safety Analysis in HYSYS.

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 Add PSV
Select location of PSV to release stream

 Click to PSV

Determined operating pressure and temperature also design pressure and temperature.
 Scenario Selection

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Click on the create scenario and then select on type scenario for selection

 Sizing Orifice
The first step is determined stream and calculation relieving temperature base on checking
stream in simulation then select the relieving phase method and required relieving flowrate.
And the last is select the orifice diameter for selection orifice, be sure selected orifice is
more than calculation orifice

 Relieving Condition
Used to indicate the inlet pressure and temperature of a pressure relief device at a specific
overpressure. The relieving pressure is equal to the valve set pressure (or rupture disk burst pressure)

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plus the overpressure. The temperature of the flowing fluid at relieving conditions may be higher or lower
than the operating temperature.
The rule of relieving pressure is following API 520 page 39.
 Back Pressure
Pressure that exists at the outlet of a pressure-relief device or depressuring valve as a result of the
pressure in the discharge system.
Back pressure = Built Up Pressure + Superimposed Pressure

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9 STARTING FLARE HYDRAULIC (ASPEN FLARE SYSTEM ANALYZER)

9.1 Input Composition

The first step before starting simulation is input the composition. In this training, component is
determined with process simulation and after simulation is finish, result will be input.

For hypothetical data, minimum information data for available is two. It is can to estimate other
data for starting simulation. Hypothetical data is determined from section 3.4

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9.2 PSV Design

Data from PSV calculation in aspen HYSYS shall be input to aspen Flare System Analyzer to
starting simulation.

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9.3 Flare Network

PSV data that have been inputted, shall be connected with other PSV to create network.

In pipe, length, fitting and connection shall be inputted. Furthermore, determine pipe is tail pipe
or not, because criteria design selection for tail pipe and header is difference.
Network shall be connected until flare tip

9.4 Criteria Design Selection

PSV data that have been inputted, shall be connected with other PSV to create network. The first
is select the scenario and the input the criteria design.

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 Tail pipe : Mach Number 0.7

 Header : Mach Number 0.5
 Noise : 100 dB

9.5 Result and Evaluation

Check on the summary in every pipe and compare with section 10.4

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THANK YOU
AND KEEP LEARNING !

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