Kuppusamy Uthman - koc kuwait

2nd Kuwait Lab Technology 2011

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Feb 1 & 2 , 2011, Radisson SAS Hotel, Kuwait

KOC experience: Greener chemicals approach and lab testing

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Background• Kuwait Oil Company

(KOC) - SEK Directorate

• 14 Crude Gathering Centers (GC)

• 2 Effluent Water Disposal Plants (EWDP)

• Total Oil Production = > 1 MM BOPD

• Total Water Disposal = 460,000 BWPD

• Design -500,000BWPD

Greater Burgan

Kuwait Oil Fields

EWDP-1

EWDP-2



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Total Chemical drums per year : 50,950!

1.Demulsifier-I : 22,500 drums

2.Demulsifier-II: 6000 drums

3.Scale inhibitor GC: 4000 drums

4.Corrosion Inh GC: 4,000 drums

5.Scale inh. EWDP: 4000 drums

6.Corrosion Inh EWDP: 4,000 drums

7.Oxygen Scavenger: 2250 drums

8.Rust & Oxidation Inh.: 200 drums

9.Biocide A : 2000 drums

10.Biocide B .: 2000 drums


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1. Shift mode of supply to Bulk containers from drums

2. Mega Storage facility for 3 months stock- KD 14 million

3. Chemicals selection based on Hazard classification

4.Lab Screening/ Field trials for efficiency

5.lab testing –innovative techniques eliminate CFC solvents

6. Data capture Sahala – global award for DM

Greener approach by KOC


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14 SEK

3 NK3 WK

GC

GC

GC/EWDP

EWDP

EWDP

GC

Bulk supply TANKERS-

20 kl

Primary Storage Tank

Demulsifier Type I

Demulsifier Type II

Scale

Corrosion

Demulsifier Type I

D.Tanker

Filling Connection

EF1672

EF1492

EF1492

EF1445

14 SEK3 NK1 WK

EF1672

2. BULK HANDLING FLOW CHART (EF 1672)

Type I4,000

18 Nos Fence

Corrosion

Scale

EF1492EF1672

Day Tanks

Oxygen

Corrosion

Demulsifier Type II

Scale

Type II4,000

2 Nos

GC

Demulsifier Type I

2 WK

EF1445

EF1445 completed

EF1672

14 SEK

3 NK3 WK

14 SEK3 NK

3WK2 EWDP

Secondary Storage Tank

2 EWDP

2 EWDP

EF1672

EF1672

GC

GC

147,000

GC

75,180

42,420

42,420

42,420

205,296 to 55000

( # in usg)

( # in usg)

Corrosion

Oxygen Scavenger

Scale

147,000

205,296 to 55,000

EF1672

50 gpm

50gpm

Adjustment Order for 2 Biocide tanks – 55,000 usg each


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¨ HSE improvement, cleaner assets¨ KOC image boost as first implementer in GCC/world? ¨ No more empty drums accumulation¨ No more chemical left over in the drums- SAVINGS¨ No more expired chemical drums ¨ No more chemical spillage due to rupture of drums¨ Safe Chemical Handling- no rolling of drums, fumes¨ Better interaction with chemical ¨ no shortage of chemicals- high volume stock available

BULK HANDLING CHEMICAL- ADVANTAGES


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3. Chemicals selection/classification:


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4. Chemical screening- example of corrosion inhibitor

Corrosion Inhibitor Selection


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Corrosion Inhibitor Dosage Rates and Residuals

0

10

20

30

40

50

60

70

1-M

ay-0

6

1-J

ul-0

6

1-S

ep-

06

1-N

ov-0

6

1-J

an-

07

1-M

ar-0

7

1-M

ay-0

7

1-J

ul-0

7

1-S

ep-

07

CI (p

pm

)

CI Dosage Rates

CI Residual (Outlet)

Recommended Injection (10-20 ppm)


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Corrosion Rates –sample

Sample # Sequence


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0

3

6

9

12

15

1-M

ay

-06

1-J

ul-

06

1-S

ep

-06

1-N

ov

-06

1-J

an

-07

1-M

ar-

07

1-M

ay

-07

1-J

ul-

07

1-S

ep

-07

OS

(p

pm

) OS Dosage Rates

OS Residual (Outlet)

Recommended Injection (< 15 ppm)

Chemical optimization


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¨ Current methods: Oil in water ¨ EPA US-1664A- HEM (Hexane

Extractable Material)- light ends evaporation.

¨ North sea- OSPAR-Oslo Paris convention new pentane extraction followed by GC-FID

¨ Kuwait – pure analytical grade chloroform/ S-316 solvent

23


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New Equipment

SCF OIW analyzer Gas chromatograph

FLASH POINTH2S ANALYZER


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The TD-500D is a dual channel, handheld fluorometer designed for quick easy &reliable measurement of Crude oil It is ‘NO SOLVENT’ Method Compatible with all popular solvent extraction methods .

¨ The TD-500D responds to the fluorescent aromatic compounds in the target hydrocarbon.¨ The instrument must be calibrated by measuring the intensity of fluorescent light that is generated by a known

concentration of hydrocarbon.¨ Once calibrated, the instrument converts the fluorescent light intensity from unknown sample into units of concentration. The ‘No Solvent Method’ makes possible to perform Oil in water analyses by making fluorescence measurement directly

on the produced water samples . No Organic solvents are required. The method is based upon the addition of a proprietary surfactant to the sample followed by heating, cooling & filtered

into a measurement cuvette. The OIW Sample contains dispersed oil that has been solubilized by OIW Surfactant. A second sample called WSO sample, contains no surfactant . It is simply filtered into a measurement cuvette to remove

dispersed oil, leaving only WSO. Both the OIW &WSO cuvettes are measured by the TD-500D. The dispersed oil concentration is calculated by subtracting the ‘WSO’ measurement from the ‘OIW’ measurement. The

result is reported in ppm.

Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used. Minimum Detection limit is <1 ppm for most oils. Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used. Minimum Detection limit is <1 ppm for most oils.¨ limit is <1 ppm for most oils.

Oil in water fluorescence meter..-solvent free


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Oil in water comparison reportSAMPLE

LOCATION

OIW BY GENESYS -20

(Extraction method) ,ppm

OIW BY TD500D Oil in water meter,

RemarksSample Blank reading

Sample reading after

surfactantResult

IMFH 17.60 -1.00 18.10 19.10 FILTER INLET 13.7 -1.6 23.5 25.10

DISPOSAL OUTLET 11.30 -1.80 19.60 21.40

GC- 8 Effluent water

16.30 -1.50 21.90 23.40


8.4 -0.7 3 3.70


9.1 -1.3 3.7 5.00

BG -551 DISPOSAL 32.20 -1.90 29.60 31.50

BG -551 DISPOSAL 12.30 -1.40 17.10 18.50

INJECTION WELL 132

12.7 -1.5 16.4 17.90


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Well test data

Data suspicio

us?

Gas

Yes

LT-II carries out analysis

Customers accept data

online

Gas LabLT-I

enters data in FINDER

Gas cylinders returned to

GO

LT-I/II enters data in FINDER

Chemist approves

data online

Samples stored for 24 hours then discarded

LT-II carries out analysis

Samples taken

Lab receiving area

-Apply labels-Print log in form-Carry in case

-Sign log in form-Use sample trays

Oil

Yes

Water Water Lab

Sample

type?

Repeat sampli

ng?

Operators access data from FINDER

Data stored in Master

Database

6. Data capture in ShahalaSample & Data Flow Process Diagram

All other data

Yes

No

Oil Lab

LT-I carries out analysis

-Apply SOPs-homogenizer


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Salt (PTB) QC X-CHART

2.12.32.52.72.93.13.33.53.73.94.14.3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sample #

Sal

t Con

tent

(PTB

)

UCL

UWL

LWL

LCL


29


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THANK YOU

Questions ??

Business

Kuppusamy Uthman - koc kuwait