G6120 Basic Engineering _rev0

uop UOP N.V., Noorderlaan 147, B-2030 Antwerp, Belgium

PROJECT SPECIFICATION Number Rev. E-G6120 0 Sheet : 1 of 42 By : T Cnop

KADANWARI PLANT EMISSION REDUCTION PROJECT BASIC ENGINEERING

UOP JOB NO. : G6120 OMV JOB NO. : 3003 OMV TENDER DOC. : 3003-12-00-10-SW-002-00 Nov. 19th 2006

STUDY : KADANWARI PLANT EMISSION REDUCTION PROJECT BASIC ENGINEERING LOCATION : KADANWARI, PAKISTAN

THIS REPORT IS PART OF THE NON DISCLOSURE AGREEMENT WITH OMV DATED JANUARY 22ND 1998

COVERING MEMGUARD AND SEPAREX SYSTEMS. THE INFORMATION IS PROPRIETARY AND SHALL NOT BE

DISCLOSED OUTSIDE YOUR ORGANISATION, NOR SHALL IT BE DUPLICATED, USED OR DISCLOSED FOR ANY

PURPOSE OTHER THAN AS PERMITTED UNDER WRITTEN AGREEMENT WITH uop

0 TC Febr. 24th 2007 First Issue TC Basic Engineering Report ID PROC. PROJ.

REV BY DATE DESCRIPTION CHK'D ISSUE APP'D




1.1 Executive summary

The process scheme selected for the basic engineering is the result of several rounds of evaluation. First the Kadanwari plant was benchmarked and all possible options and technologies were evaluated in a general Emission Reduction Study. From this evaluation, OMV withheld 3 cases, each comprising of several technologies and improvements, to be developed in detail in the FEED study. Based on the more detailed FEED study, OMV has now selected one scenario comprising of two technologies to be further developed in the present Basic Engineering. During the Basic Engineering, a HAZOP review of the subject project was held. The HAZOP report is included and the PIDs updated. As introduced in the previous extensive emissions study and FEED study, the selected scenario, which is the result of an in depth review by OMV and UOP, is very promising in terms of hydrocarbon recovery and related emissions.

CO2 - introduction

CO2 emissions are inherent to the objective of the Kadanwari facility, treating the Kadanwari and Miano gas to pipeline specification. Reducing the CO2 content from 10.5% to 3% in a 220MMscfd production generates an inherent CO2 stream of 16.5MMscfd of pure CO2, corresponding to approx 0.35MMt/y of CO2. In addition CO2 is generated in the combustion of 4-5Mmscfd of fuel gas (equivalent to 0.09MMt/y CO2). Finally, the separation of natural gas and CO2 is not a perfect separation and a small fraction of hydrocarbons is lost. These hydrocarbons contribute to the emissions when incinerated (0.09MMt/y CO2) or when vented. Venting hydrocarbons is much less favourable than incinerating the hydrocarbons in terms of greenhouse effect. The most promising option to reduce CO2 emissions is to tackle the 0.09MMt/y of emissions related to the hydrocarbon losses in the vent gas (see next section). These CO2 emissions represent 0.09MMt/y = 17% of the total CO2 emissions. For the remaining 83% of the emissions (=inherent CO2 emission), venting is the more economical option, unless when a specific incentive exists. Producing a commercial CO2 product (food grade, urea production or EOR) or Reinjecting the CO2 in a depleted well are technical options that were not withheld for the Kadanwari facility.

Hydrocarbons - introduction Hydrocarbon losses are linked to

Membrane operation: the separation of methane and carbon dioxide does not have an infinite selectivity. Some hydrocarbons permeate with the CO2 in the vent gas;

The low pressure gas released when depressurising the MemGuard unit (combined temperature and pressure swing unit) consists of 80% methane and is sent to the vent.

UOP has reviewed the current operation in great detail to reduce the hydrocarbon emissions, resulting in an increased hydrocarbon recovery (= increased revenue). The most promising options have resulted in the definition of scenario for the basic engineering:

Installation of MemGuard after coolers Installation of a UOP PSA unit




Conclusion for CO2 emissions and Hydrocarbons The CO2 emissions are reduced and at the same time the Hydrocarbon recovery is increased (Revenue):

Compared to the existing situation (= reference case), the increase in hydrocarbon recovery (on a fuel excl. basis) is 2.17%.

The hydrocarbons in the vent stream, which are incinerated, currently represent 0.09MMt/y of CO2 emissions (=17% of the total CO2 emissions). Recovering these hydrocarbons reduces the CO2 emissions by -15%.

The hydrocarbons currently lost in the vent gas (= reference case) represent an increased revenue of approximately 5.2 MM$/year (based on the OMV data of 3.0$/kscf & 220MMscfd feed gas).

H2S emissions - introduction

UOP has reviewed the wide range of sulphur treating technologies available on the market to treat the H2S in the vent gas to meet the NEQS levels (10mg/Nm3 H2S = 6.6vppm; 1700mg/Nm3 SOx = 595vppm in terms of SO2). The vent gas is characterized by a diluted (




Table of Contents

1.1 EXECUTIVE SUMMARY .......................................................................................................2 1.2 SCOPE..............................................................................................................................5 2.0 INTRODUCTION..................................................................................................................6 2.1 POTENTIAL........................................................................................................................6 2.2 REFERENCE CASE .............................................................................................................6 3.0 MEMGUARD AFTER COOLING USING TRIM COOLERS..........................................................8 4.0 VENT GAS PRESSURE......................................................................................................12 5.0 VENT GAS ANALYSIS .......................................................................................................13 5.1 VALIDATION OF UOP MODEL BASED ON VENT GAS ANALYSIS ...........................................14 6.0 PSA UNIT........................................................................................................................15 6.1 INLET TEMPERATURE OF THE PSA UNIT ...........................................................................18 7.0 RECOVERING THE DEPRESSURIZATION GAS......................................................................19 8.0 PSA VENT GAS DATA FOR COMPATIBILITY CHECK WITH INCINERATOR............................23 8.1 QUANTITAITVE DATA OF PSA VENT GAS ..........................................................................24 8.2 CONCLUSION ON TAIL GAS DRUM .....................................................................................24 9.0 PSA FEED GAS COMPRESSOR PACKAGE DESIGN BASIS ................................................25 10.0 CLOSE OUT OF HAZOP REPORT - FEED .........................................................................27 11.0 HAZOP REPORT BASIC ENGINEERING ..........................................................................31

Attachment 1: Process Flow Diagram for Kadanwari Plant Attachment 2: Block Diagram for Kadanwari Emission Overview Attachment 3: Kadanwari Recycle Compression System Attachment 4: G6120-002/04 PID integration MemGuard aftercoolers Attachment 5: G6120-002/01-02-03 PID integration of PSA unit Attachment 6: H2741-001 Proces Flow Diagram. PSA unit on Vent Gas Attachment 7: H2741. Proposal for PSA unit on Vent Gas. Rev 1 Attachment 8: MemGuard after cooler design basis Attachment 9: Solar proposal for PSA feed compressor with typical PIDs Attachment 10: OMV Kadanwari PFD & PIDs Attachment 11: HAZOP report




1.2 Scope

OMV Pakistan previously awarded a FEED study to UOP to develop possible options to reduce the Kadanwari Plant Emission. From the FEED study the following options were selected by OMV & JV partners for further development in basic engineering (refer to Basic engineering Scope 3003-12-00-10-SW-002-00 by OMV dd. November 19th 2006):

Installation of MemGuard after coolers to minimize the T-spike at the membrane inlet Installation of a PSA unit on Vent Stream to recover 90% of the HCs from the Vent Gas As the PSA tail gas enriched in H2S will need to be incinerated, the compatibility of the

existing incinerator is to be evaluated

Refer to the Basic engineering Scope 3003-12-00-10-SW-002-00 by OMV, Nov. 19th 2006 The basic engineering has as aim to

1. confirm the design basis 2. define a scope of supply and process & integration compatibility of supplied items with the

existing systems. Page 4 of 9:

UOP has suggested to optimize the PSA / PSA feed compressor. However, OMV has provided input that the feed conditions to the PSA feed compressor cannot be changed, see secton 4.0 (Vent Gas Pressure).

With exception of the review with respect to operability of the PSA unit, the PSA feed compressor, the after coolers and KO vessels, the review with respect to operability of the system is not in UOP scope.

UOP will propose the minimum requirements for the MemGuard aftercooler operation & controls. However, any detail with respect to the cooling water system is not in UOP scope.

Page 4 of 9, deliverables:

PFD and PID refer to a typical PFD / PID for the MemGuard after coolers and detailed PID of the PSA unit (as already included in the PSA technical proposal and reviewed in the preliminary HAZOP)

Integrated model will not take transient temperature changes into account Tie-in details are limited to battery limit connections of PSA, feed compressor, feed

compressor after cooler and MemGuard after coolers Operating control philosophy is limited to the interface between the PSA and PSA feed

compressor and the OMV system (including required bypass, how to SD) and the control loops on the MemGuard after coolers. ESD is out of UOP scope. Specifically for the bump cooler, UOP will provide details on

o Requirement of bypass o Control loops o Depressurization rates o Utilities

Plant hydraulics relates to o Battery limit pipe sizing o Requirements on low Dp piping outside UOP B.L.

Materials of construction are already detailed in PSA technical proposal Equipment specs relate to process datasheets for exchangers / compressor / compressor

aftercooler Instrument specs relate to special requirements on valves U/S or D/S of UOP B.L. Electrical data sheets is only relevant in case of electrical motor for compressor Equipment GA refers to PSA GA. Design Codes and Standards are included in the PSA technical proposal




2.0 Introduction

2.1 Potential

The installation of a PSA unit will result in an increased recovery of hydrocarbons o Reference case: 97.47% (HC recovery on fuel-excl basis) o With PSA unit: 99.64%

90% of the hydrocarbons currently lost in the depressurizing gas can be recovered in the PSA unit (refer to the previous study). Based on the OMV supplied number of 3.0$/1000scf, the increased HC recovery equivalent to approximately 90% x 0.62MMscfd x 3.0 $/kscf =0.6 MM$/year. Recovering 90% of the hydrocarbons from the current vent stream would result in a saving of 0.08MMt/y of CO2 emissions (=15% of the total CO2 emissions) and an additional revenue of approximately 90% of (20% hydrocarbons x 24MMscfd) x 3.0 $/kscf = 4.6 MM$/year The total potential is

for 220MMscfd throughput: 0.08MMt/y of CO2 emission reduction (=15% of the total CO2 emissions) 5.2 MM$/year additional revenue ((99.64-97.47%)*220MMscfd*3.0$/kscf)

for 240MMscfd throughput: 0.09MMt/y of CO2 emission reduction (=15% of the total CO2 emissions) 5.8 MM$/year additional revenue ((99.64-97.47%)*240MMscfd*3.0$/kscf)

2.2 Reference case Simulations are for 240MMscfd raw feed gas flow in 60/40 ratio (144MMscfd Miano gas and 96MMscfd Kadanwari gas) The performance of the PSA + MemGuard after coolers is compared with the reference case as presented below. The reference case includes an increased feed flow of 240MMscfd the impact of the depressurization losses is included by sending a time-averaged MemGuard

product slip stream of 0.62MMscfd into the vent gas the impact of the non-stationary effects due to the heat bump is not presented in the material

balance




Reference case (UOP Hysys Case 1a)

Raw feed Raw feed MG Feed MG Feed FC liquids FC liquids Mem 1 feed (incl 4N)

Mem 1 feed (incl 4M)

Mem 1 res Mem 1 res Sales gas Mem 1 perm

Mem 1 perm

Recycle compr feed

Mem 2A feed =

9N+9M UOP Stream Name 1N 1Q 1A 1B 20P 20Z 3N 3L 5N 5H 5K 6N 7N 8N compr

outlet Pressure, psia 1290 1290 1269 1269 1282 1282 1248 1248 1232 1226 1219 32 32 32 1330 Pressure, bar_g 87.9 87.9 86.4 86.4 87.3 87.3 85.0 85.0 83.9 83.5 83.0 1.2 1.2 1.2 90.7 Temperature, F 110 110 80 80 81 81 83 83 65 65 100 69 69 69 115 Temperature, C 43 43 27 27 27 27 28 28 18 19 38 21 21 21 46 Molar Flow, lbmole/h 13177 13177 13164 13164 0 0 14511 14511 11710 11741 23452 2801 2770 5571 5571 Molar Flow, MMSCFD 120.0 120.0 119.9 119.9 0.0 0.0 132.2 132.2 106.6 106.9 213.6 25.5 25.2 50.7 50.7 Molar Flow, Nm3/h(gas) 133965 133965 133842 133842 0 0 147534 147534 119057 119375 238431 28477 28159 56636 56635 Mass Density, lb/ft3 4.888 4.888 5.270 5.270 63.022 63.022 5.136 5.136 4.637 4.608 4.103 0.171 0.171 0.171 8.338 Molecular Weight 19.72 19.72 19.72 19.72 18.09 18.09 19.78 19.78 17.40 17.40 17.40 29.72 29.87 29.79 29.79 Composition, Mole Fraction Water 0.001519 0.001519 0.000656 0.000656 0.997125 0.997125 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000 Hydrogen sulfide 0.000025 0.000025 0.000025 0.000025 0.000002 0.000002 0.000024 0.000024 0.000004 0.000004 0.000004 0.000105 0.000106 0.000105 0.000105 Nitrogen 0.010649 0.010649 0.010659 0.010659 0.000011 0.000011 0.010487 0.010487 0.011689 0.011667 0.011678 0.005456 0.005477 0.005466 0.005467 Carbon dioxide 0.112430 0.112430 0.112527 0.112527 0.002862 0.002862 0.117191 0.117191 0.029499 0.029500 0.029500 0.484156 0.489298 0.486713 0.486720 Methane 0.857372 0.857372 0.858147 0.858147 0.000000 0.000000 0.855687 0.855687 0.939207 0.939383 0.939295 0.506176 0.500532 0.503370 0.503378 Ethane 0.013810 0.013810 0.013822 0.013822 0.000000 0.000000 0.013070 0.013070 0.015330 0.015227 0.015278 0.003611 0.003915 0.003762 0.003762 Propane 0.001910 0.001910 0.001911 0.001911 0.000000 0.000000 0.001805 0.001805 0.002149 0.002114 0.002132 0.000363 0.000493 0.000428 0.000428 i-Butane 0.000621 0.000621 0.000622 0.000622 0.000000 0.000000 0.000575 0.000575 0.000699 0.000692 0.000695 0.000059 0.000080 0.000069 0.000069 n-Butane 0.000312 0.000312 0.000313 0.000313 0.000000 0.000000 0.000289 0.000289 0.000351 0.000348 0.000350 0.000029 0.000040 0.000035 0.000035

Mem 2A res Mem 2B res Mem 2A+2B

perm

Perm gas not used for MG regen.

Closed loop regen make-

up gas

Regen gas (heating)

Regen gas (cooling)

Combined spent regen

gas

Closed loop Spent regen gas recycle

Closed loop Spent regen gas bleed to

vent

Combined vent

PSA feed compressor

suction

PSA feed PSA vent gas

PSA product gas

recycle

UOP Stream Name 11N 13N 15N To Vent 3A 3B Spent Regeneratio

n

8A Combined

Vent

Pressure, psia 1268 1262 50 50 45 49 23 23 Pressure, bar_g 86.4 86.0 2.4 2.4 2.1 2.3 0.6 0.6 Temperature, F 46 55 49 49 550 49 231 198 Temperature, C 8 13 9 9 288 9 111 92 Molar Flow, lbmole/h 3318 2782 2789 461 1164 1164 2354 2883 Molar Flow, MMSCFD 30.2 25.3 25.4 4.2 10.6 10.6 21.4 26.3 Molar Flow, Nm3/h(gas) 33735 28282 28353 4686 11834 11834 23931 29309 Mass Density, lb/ft3 7.412 6.088 0.363 0.363 0.160 0.352 0.121 0.126 Molecular Weight 23.23 20.74 38.82 38.82 38.82 38.82 39.01 38.52 Composition, Mole Fraction Water 0.000000 0.000000 0.000000 0.000000 0.000000 0.000000 0.007339 0.005992 Hydrogen sulfide 0.000026 0.000013 0.000197 0.000197 0.000197 0.000197 0.000195 0.000191 Nitrogen 0.007730 0.008759 0.002183 0.002183 0.002183 0.002183 0.002159 0.002363 Carbon dioxide 0.249953 0.159998 0.812618 0.812618 0.812618 0.812618 0.803659 0.788773 Methane 0.736193 0.824314 0.183252 0.183252 0.183252 0.183252 0.181233 0.197562 Ethane 0.005194 0.005860 0.001669 0.001669 0.001669 0.001669 0.001651 0.001941 Propane 0.000677 0.000787 0.000070 0.000070 0.000070 0.000070 0.000069 0.000113 i-Butane 0.000113 0.000133 0.000006 0.000006 0.000006 0.000006 0.000006 0.000020 n-Butane 0.000057 0.000067 0.000003 0.000003 0.000003 0.000003 0.000003 0.000010

Note: 8N = 6N + 7N + depressurization gas + PSA product recycle gas

Simulated hydrocarbon recovery = 97.47% (not accounting for fuel consumption)




3.0 MemGuard After Cooling using Trim Coolers

The current operation shows a temporary increase in vessel outlet temperature when a freshly regenerated MemGuard vessel is brought online (adsorption/transition step). To buffer the increase in membrane feed temperature, a transition step is designed in the MemGuard unit, during which, both adsorption vessels of the same train are online. The readings are based on spot monitoring of data on 19th Oct 05.

MemGuard train I - Heat bump when fresh vessel is brought onlineDuring the first 30 min. (transition step), the fresh and old vessel are both online

0

20

40

60

80

100

120

140

160

8:42:35 8:52:26 9:02:16 time

T (F)

MemGuard vessel on adsorption outlet

MemGuard vessel in transition

Average outlet(adsorption + transition)

Still, the temperature bump propagates through the system:

The temperature bump reaches the 1st stage membranes, propagates through the primary membrane residue (sales gas) and exchanges heat with the raw feed gas in the feed coolers (E-0520/0525), after which, it again reaches the MemGuard inlet. This recycle causes the actual temperature bump to be extended in time

The temperature bump reaches the 1st stage membranes, increasing the permeation rate. As a consequence, the permeate compressors have to handle more permeate.




Propagation of temperature bump through the system

60

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140

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160

8:30:46 8:50:27 9:10:09 9:29:50 9:49:31 10:09:1 10:28:5 10:48:3 11:08:1time

T (F)

MemGuard Train 1 outletMembrane Train 1 inleat (incl recycle stream) MemGuard Train 1 inlet

The current operation shows a temperature increase at the outlet of the fresh MemGuard bed (prior to mixing with the outlet of the 2nd bed) during approximately 30minutes with a peak of +45F. In the transition step, this peak is reduced by half before entering the membranes. The temperature bump propagates in the sales gas and is consequently recycled upstream of the MemGuard through cross exchange in the feed coolers. This further extends the temperature bump. The raw gas (upstream of the MemGuard), after cross exchange in the feed coolers, has a temperature increase of 90 minutes with a peak of +12F.

The permeate compressor flow (combined from Train 1 and Train 2) varies from 43 to 48MMscfd. 157minutes (half of 315minutes) after the first train, the next MemGuard train generates a temperature bump.

Effect of membrane temperature on compressor flow

60

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8:30:46 8:50:27 9:10:09 9:29:50 9:49:31 10:09:1 10:28:5 10:48:3 11:08:1time

T (F)

0

12

24

36

48

60

Flow (MMscfd)

MemGuard Train 1 outletMembrane Train 1 inleat (incl recycle stream) MemGuard Train 1 inletPermeate compressor flow




Due to the increased permeation on the primary membranes, the 2nd stage residue flow (recorded at recycle skid B outlet) increases from 20 to 25MMscfd with a corresponding temperature increase of 4F (from 58 to 62F). The effect starts simultaneously in 1st and 2nd stage membranes but it lasts for 30 min. in 1st stage and for 2 hours in 2nd stage membrane system.

The UOP MemGuard modeling shows that the temperature spike is not a result of residual heat (incomplete cooling) in the regenerated MemGuard vessel, but is inherent to the adsorption process itself. It is important however to minimize the temperature bump and eliminate the propagation of this effect which affects the operation during a period of almost 1.5 hours.

UOP suggests to install heat exchangers (MemGuard After Coolers) upstream of the existing primary membrane skids, as was already proposed in the 300MMscfd expansion project (E-0531 and E-0536). If a compact (Heatric) type exchanger is used (as already used in the pre-treatment skids), the installation between the particle filters and the membrane skid is fairly easy. Initially gas-gas cross exchangers were suggested using the sales gas (200MMscfd) as a cooling medium. However, to avoid the possible nuisance of a varying temperature at the inlet of the sales gas compressors, OMV has selected water trim coolers instead. 1. Simulation The temperature spike in the MemGuard unit is a transient process that is not reflected in the overall material balance. 2. Process Benefits (in terms of emission and/or hydrocarbon recovery)

Eliminates the fluctuations on the permeate compressor (5MMscfd). These fluctuations translate into a temporary increased power demand, increased difficulty in controlling the plant and limit the possibilities to use the spare compression capacity in other improvement schemes. Without taking into account other improvement schemes, the net saving is a power saving with a fuel decrease of 0.3MMscfd * 30min/157min = 0.06MMscfd.

No significant impact on the overall hydrocarbon recovery, as long as the recycle compressor has sufficient capacity to handle the variations in permeate flow. In case of shortage in compression power (e.g. With increasing feed gas flow rates to 240MMscfd or after implementation the PSA unit), the impact on the hydrocarbon recovery becomes very important, as excess permeate gas will have to be flared.

Eliminates the fluctuations on the membranes. This facilitates a more accurate adjustment to 3.0% CO2 in the sales gas.

3. Sizing / Duty The Cooling water at Kadanwari is specified as:

Supply temperature Return temperature Wet bulb temperature Dry bulb temperature

90 0F 110 0F

84F 119F

As the cooling tower has been upgraded taken in view of 3rd train addition, a lot of room is available to bear more heat load. At current operation, the supply temperature is around 85 0F and return temperature is 97 0F.




Each cooler (one per train) should be able to cool 120MMscfd of feed gas by 25F from 125F to 100F. This corresponds to a net duty of 3.76MMBTU/hr (per train) Notes:

The sizing (Attachment 8) is for one cooler. Two coolers are required (Train I & II) The attached sizing does not include design margin (typical 10% on flow and duty) Each cooler will operate intermittendly for about 30 minutes in a 315minutes cycle. As

such: o The maximum flow of cooling water required for both coolers combined is the

cooling water flow for one single heater. o The maximum duty of cooling water required for both coolers combined is the

cooling water duty for one single heater. o The averaged duty = 2*30min/315min * max duty = 0.19 * max duty

The PID is shown in Attachment 4 Suggested changes on the PID

Addition of TIT on The datasheet is shown in Attachment 8




4.0 Vent Gas pressure

In order to recover the vent gas in a PSA unit, the low pressure vent gas (20psia) needs to be recompressed. In order to reduce the PSA feed compressor duty, UOP has suggested to increase the membrane permeate pressure. It is expected that the impact on the membrane operation and MemGuard regeneration would be minor. a. Increase of Membrane permeate pressure to 80psia

MemGuard regeneration gas at 80psia Vent at 50psia

b. PSA unit operating at PSA feed at 120psia PSA feed Compression from 45psia to 135psia (note: the compression ratio is

selected to fit in a single To verify impact, UOP asked to perform a plant test run to generate the following operating data at 17, 37 & 57 Psia vent header pressure:

Plant Feed Composition Recycle Compressor Feed Composition Gas Composition of Vent Gas outside the depressurization step Gas Composition of Vent Gas during the depressurization step.

OMV informed that they were not able to generate and collect data from the site with respect to increased 2nd stage permeate pressure as discussed in the meeting with OMV. OMV will go-ahead with the option of base case having 50 psia as 2nd stage permeate pressure and 17 psia vent pressure which requires approximately 4 MW PSA feed compressor as this option will have least affect on the existing plant operation instead of selecting a lower 2 MW compressor but compromising to a certain extent on the plant operating conditions. OMV lists several reasons including the Plant operations team is not fully convinced to run the plant now or even later under these conditions as it is believed this may cause:

Overloading of the 2nd stage permeate compressor to a certain extent MemGuard regeneration loop can be affected Less degree of freedom to operate the 2nd stage membrane skids due to increase in

permeate pressure Consequently overall membrane performance could be affected

Conclusion: definition of design basis (= Alternative case 4 from the FEED study)

Current membrane permeate pressure o Membrane permeate pressure 50psia o Vent gas at 20 psia

PSA unit operating at o PSA feed at 120psia o PSA feed Compression from 17 psia to 135psia




5.0 Vent Gas Analysis

The analysis report shows the Gas samples collected during Memguard Depressurization step. Depressurization step was from 1425 HRS to 1450 HRS. of V1205A (samples at 1430, 1437 & 1445 HRS).




As the flow rate of the depressurization gas is not measured at site, OMV agreed to use the number of 3.88Mmscfd average depressurization flow rate previously calculated in the study The permeate and vent analysis shows three times 78% and one time 80% CO2. No errors in analysis were suspected by OMV and as such it is proposed to use the average value of both measurements.

5.1 Validation of UOP model based on Vent Gas Analysis

The UOP model is validated using the attached analysis report (Nov 18-22). Operating the plant At 218.88MMscfd Without closed loop Without mixing depressurizing gas in the vent gas The model predicts a vent flow characterized by

Simulation Case 60 Stream Name 12b Pressure, psia 17 Temperature, F 82 Molar Flow, MMSCFD 23 Composition, Mole% Water 0.61 Hydrogen sulfide 0.02 Nitrogen 0.22 Carbon dioxide 80.48 Methane 18.28 Ethane 0.17 Propane 0.01 i-Butane 0.00 n-Butane 0.00 Molecular Weight 38.84

The difference between model and site-measurements are :

Simulation Case 60 Nov 18 Nov 22 Stream Name 12b Analysis Deviation Analysis Deviation Pressure, psia 17 44 17 Temperature, F 82 83 100 Molar Flow, MMSCFD 23 22.5 -2% 22.8 -1% Composition, Mole% Water 0.61 - - Hydrogen sulfide 0.02 - - Nitrogen 0.22 0.15 0.40 Carbon dioxide 80.48 78.59 -2% 80.37 +0% Methane 18.28 20.73 +13% 18.85 +3% Ethane 0.17 0.35 0.24 Propane 0.01 0.17 0.14 i-Butane 0.00 0.00 0.00 n-Butane 0.00 0.01 0.00 Molecular Weight 38.84 38.14 -2% 38.64 -1%

Conclusion: The site data are in good approximation with the model. As such the model can be used to estimate the overall performance of the plant (recovery, compression flows, recycle flows) in presence of the PSA unit.




6.0 PSA unit

A PSA unit can recover >90% of the methane in the vent gas. The PSA unit operates at a higher pressure and therefore requires feed compression (to 120psia). The methane recovery in a PSA unit can be traded off:

lower methane recovery, less recycle compression, with lower CO2 purity in vent gas higher methane recovery, higher recycle compression, higher CO2 purity in vent gas

The PSA feed compressor can be a centrifugal compressor, a piston compressor or even a screw compressor. UOP has designed over 800 PSA units including 25 PSA systems with over 40 compressors.

Selection of the recycle point of the recovered hydrocarbons:

In principle, the hydrocarbons recovered in the PSA product gas (at medium pressure) can be recycled to an inter-stage pressure of the permeate compressor to reduce the power consumption of the permeate compressor. However, OMV has indicated that the PSA product gas should be mixed with the membrane permeate gas at the low pressure suction of the permeate compressor. This avoids operational changes and variations on the permeate compressor. In this case the operating pressure of the PSA unit is selected independently for optimum PSA performance and minimum PSA feed gas compressor power consumption. The optimum PSA feed pressure is 120psia which corresponds to a compressor discharge pressure of 135psia.

Requirement of a tail gas drum:

The typical PSA PFD includes a tail gas drum (= vent gas drum) to buffer the low pressure tail gas when it is sent to burners. The requirement of a tail gas drum is discussed in section 8. The current PSA proposal is exclusive of a tail gas drum.

Typical peripheral flow scheme and controls:

Figure: Peripheral flow scheme for a PSA unit

Note: The actual PSA controls for this project are detailed in the PID in attachment 5.




Figure: PSA unit

General note: The simulations are based on the base case as described in the scope of work. For 200MMscfd this corresponds to a permeate flow rate of 43MMscfd. When increasing the feed to 240Mmscfd this further increases to 51Mmscfd. As this approaches the design capacity of the permeate compressor of 60MMscfd, one could judge that further improvements are not possible. However, even though some of the presented options indicate compression flows exceeding 60Mmscfd, one should keep in mind that: the actual membrane performance is better than reflected in the material balance (which

assumes end-of-life performance). As such the compression flows in the simulations are overestimated.

the Kadanwari plant & PSA unit might not be operated at its design throughput of 240MMscfd

the base case of the PSA unit includes the depressurization gas which occurs during only 25 minutes per 157minute cycle.

At all times, the PSA operation can be adjusted such that the combined compression feed stream is matched exactly with the actual compression capacity. The combined recycle compression stream consists of: first stage permeate gas recycle of PSA product gas.




Methane PSA reference list: Note: UOP has supplied over 800 PSA units worldwide, the reference mentioned below are for C1 & C2 applications User Country Feed Source Feed Flow Feed Product Flow Startup Nm3h Barg Nm3h USA Miscellaneous off-gas USA Natural Gas 1973USA Natural Gas 860 13.1 406 1974USA Confidential 94.89 15.17 35 1977Russia Natural Gas 2130 11 900 1979USA Natural Gas 1980USA Natural Gas 603 13.79 314 1980Russia Natural Gas 2130 11 900 1981Canada Natural Gas 860 16.21 357 1984USA Natural Gas 7691 9.79 3181 1985Saudi Arabia Natural Gas 4375.9 11.59 2333 1985Russia not defined 2680 10 1165 1987Canada Natural Gas 1172 22.07 558 1988USA Natural Gas 2478 17.24 1267 1990USA Ethylene off-gas 1529 25.86 643 1991USA Natural Gas 1462 17.59 737 1993USA Natural Gas 4342 21.72 2623 1994USA Natural Gas 2300 24.14 837 1995Belgium Natural Gas 1903 24 1203 1996Saudi Arabia Ethylene off-gas 4420.55 2367 1999Saudi Arabia Natural Gas 2026 20.5 825 2005




6.1 Inlet temperature of the PSA unit

The recycled regeneration gas has to be cooled prior to entering the regeneration gas compressor. According to the hysys model: Currently the spent regeneration gas (318F) is cross-exchanged (cooled to 216F 2.5MMBTU/hr)) in E-1215, air-cooled in E-1210 (124F 2.1MMBTU/hr) and again cross-exchanged in E-1215 (heated to 231F). This scheme is no longer feasible as the PSA feed compressor cannot be fed at 231F. The cross-exchange has to be eliminated at additional cost of air cooling E-1215 (duty 4.7MMBTU/hr) to achieve a final temperature




7.0 Recovering the depressurization gas

The MemGuard depressurizing gas is characterized as follows

Pressure (start/end) psia 1270-50 Quantity (scf) (Source: UOP MemGuard model) 67400 Duration (minutes) 25 Estimated Flow (min/average/max) MMscfd - / 3.88 / - Composition Average: 85.6% CH4, Average losses (based on average of 315min cycle time): Q(scf)*24h*60min*2trains/315min

0.62MMscfd of gas with 87% HC,12%CO2

Dep gas composition

00,10,20,30,40,50,60,70,80,9

1

0 0,1 0,2 0,3 0,4 0,5Time, h

mol

frac

tion

0,00

0,02

0,04

0,06

0,08

0,10

CH4CO2H2OC10C9

Figure: Depressurization Gas - composition as function of time

OMV has selected to mix this gas with the Vent Gas and send it to the PSA unit. If the depressurization logic is switched to flow-control (recommended), the depressurization gas introduced +3.88MMscfd additional PSA feed flow. The depressurization step takes 25 minutes every 157 minutes. The depressurization gas will be mixed with the 2nd stage permeate gas and buffered at 50psia. The PSA will see a flow rate changing from approximately 33.7MMscfd (no depressurization) to 37.2Mmscfd (depressurization). The molecular weight varies from 38.9 (no depressurization) to 36.8kg/kmol (depressurization).

Note: One could argue that in principle it should be possible to distinguish two parts in the

depressurization step: Part 1: The MemGuard depressurization gas can be sent directly (through a PCV

set at 150psia) to the PSA feed as long as the MemGuard pressure is >200psia. This represents a quantity 88% of the complete depressurization gas with an average flow rate of 3.88MMscfd.

Part 2: As soon as the pressure drops below 200psia, the gas is sent to the PSA feed gas compressor.

The advantage of this scheme is limited to power saving on the PSA feed compressor. As the sizing of the compressor is not affected and to avoid overcomplicating the process scheme, it is preferred not to choose this scheme and to send the entire depressurization gas (1270-50psia) to the PSA feed compressor.

In presence of a PSA unit, UOP recommends to send the depressurization gas to the suction of the PSA feed compressor.




The repressurising/depressurising of the MemGuard vessels are transient processes that are difficult to reflect in the overall material balance. In reality, there is a slight fluctuation on the feed gas (at constant sales gas) or in the sales gas (at constant feed gas flow rates) inherent to the repressurising step of the MemGuard vessels. The depressurizing stream is complementary to the repressurising step. The material balance shows a slip stream of each MemGuard unit that is directed to the PSA unit. Depending on the final compressor selection, a buffer vessel on the compressor suction might be recommended to smoothen the feed flow to the PSA feed compressor. A 100m3 buffer vessel has estimated dimensions & cost of:

Vessel volume of buffer 100m3 Design pressure (psia) 70psia OD / TT / Total Height (mm) 3200 / 11500 / 15000 Weight (kg) 17000 Estimated CAPEX 60k (buffer vessel)

PSA unit at constant recovery or PSA unit at constant product flow

Operating the PSA unit at a constant recovery (90% methane recovery) results in an increased PSA product flow during the depressurization step (as the PSA feed flow increases from 33.7MMscfd to 37.2Mmscfd. The PSA product increases 12.4MMScfd (outside the depressurization step) to 15.5MMscfd. Although recycling as much of the methane recovered from the vent gas is favourable, it might exceed the available permeate compression capacity (~60MMscfd) and cause minor variations of the operating conditions. The material balance shows the combined permeate compressor feed to increase to 67.8MMscfd. If the permeate compressor capacity is exceeded, a slip stream of the vent gas will be bypassed around the PSA system using a FCV.




PSA unit design basis UOP case 61 240MMscfd with PSA No depressurization step

Raw feed 1N+1Q Combined spent regen gas upstream E-1210 3A+3B

Combined spent regen gas

PSA feed compressor suction

PSA feed PSA vent gas PSA product gas recycle

Stream Name 9 5 Spent Regeneration

12 16 PSA vent PSA product

Pressure, psia 1,290 30 23 17 125




PSA feed compressor design basis

UOP case 62 240MMscfd with PSA Including depressurization step

Raw feed 1N+1Q Combined spent regen gas

upstream E-1210 3A+3B

Combined spent regen gas

PSA feed compressor suction

PSA feed PSA vent gas PSA product gas recycle

Stream Name 9 5 Spent Regeneration

12 16 PSA vent PSA product

Pressure, psia 1,290 30 23 17 125




8.0 PSA Vent Gas Data for compatibility check with incinerator

The PSA vent gas (also called tail gas or off gas), is to be routed to the incinerator to avoid H2S emissions. Any PSA vent gas will have some fluctuations which our inherent to the PSA process (batch process). Assuming a constant flow rate (assuming ideal downstream flow control), the PSA vent gas will have some fluctuations in composition and as a consequence LHV and Wobbe (BTU/scf).

No mixing drum (cycle without depressurization gas)

42

43

43

44

44

45

45

46

46

0 20 40 60 80 100 120 time (s)

MW

0

10

20

30

40

50

60

70

80

LHV & Wobbe

MWLHV (BTU/scf)Wobbe

% fluctuation =(max-min)/avg LHV = 27.3%Wobbe = 27.7%MW = 0.84%

In addition to the compositional variations discussed above, two other variations should be addressed. The PSA vent gas with properly tuned downstream FCV will fluctuate (assuming a constant feed stream) with typical 1-3%. For design purposes a fluctuation of 5% is assumed Because of the addition of the MemGuard depressurisation gas (30minutes every 157 minutes), the feed flow to the PSA unit changes. This again induces a compositional variation as well as a flow variation. This is represented qualitatively in the chart below. For clarity the following chart is only qualitative neither absolute numbers nor scale are shown)

PSA vent gas - Qualitative

25

30

35

40

45

50

55

60

65

70

75

0 20 40 60 80 100 120 time (min)

MWFlow RateLHVWobbe




Downstream processes that cannot handle the presented variations require a so called mixing drum on the vent gas downstream the PSA unit. This is very common when for example the PSA vent gas is used as a fuel gas in steam reformers. An example can be seen in the PSA picture in section 6.0 above. Installing a mixing drum reduces the compositional variations significantly (roughly by a factor of three). Compare the qualitative representation below with the one above.

PSA vent gas - QualitativeWith mixing drum

25

30

35

40

45

50

55

60

65

70

75

0 20 40 60 80 100 120 time (min)

MWFlow RateLHVWobbe

8.1 Quantitaitve data of PSA Vent Gas

Outside depressurisation step Variations without

mix drum Variations with mix drum

PSA Product Flow to permeate compressor (MMscfd)

12.41

PSA Vent Flow (MMscfd) 21.40 5% 5% PSA Vent MW 43.2 0.8% 0.3% PSA Vent LHV(BTU/scf) 48.0 27% 9% PSA Vent Wobbe (BTU/scf) 43.2 28% 9% During depressurization step, PSA Product Flow to permeate

compressor (MMscfd) 15.53

PSA Vent Flow (MMscfd) 21.85 5% 5% MW 42.7 0.8% 0.3% PSA Vent LHV(BTU/scf) 63.7 27% 9% PSA Vent Wobbe (BTU/scf) 57.8 28% 9% During depressurization step, Constant Product Flow to permeate

compressor (MMscfd) 12.41

PSA Flow bypassed through FCV 5.97 PSA Vent Flow (MMscfd) 23.29 5% 5% MW 41.2 0.8% 0.3% PSA Vent LHV(BTU/scf) 113.0 27% 9% PSA Vent Wobbe (BTU/scf) 104.8 28% 9%

8.2 Conclusion on tail gas drum

OMV recommends not to install a tail gas drum and, instead, to take into account the above PSA vent gas variations into the design of the incinerator.




9.0 PSA Feed Gas Compressor Package design basis

The PSA Feed Gas compressor package includes PSA Feed Gas Compressor Compressor Driver (Gas Motor or Gas Tubine) Compressor inlet KO drum (if required) Compressor intercooler(s) Compressor after cooler + KO drum (process gas outlet 135F)

Fuel gas specification

Site Conditions: Ambient conditions: Maximum Temperature : Minimum Air Temperature: Site Elevation: Average Humidity: Average Rain Fall: Earth Quake Zone: Wind Velocity (max):

131 0F 25 0F 170 ft above sea level 25% 50-75mm (Usually in Jul/Aug) 2 160 Km/hr

Cooling water: Supply temperature Return temperature Wet bulb temperature Dry bulb temperature

90 0F110 0F84F

119F




Design basis

UOP case 62 240MMscfd with PSA Including depressurization step

PSA feed compressor

suction

PSA feed

Stream Name 12 16 Pressure, psia 17 125 Pressure, bar_g 0.2 7.6 Temperature, F 86 135 Temperature, C 30 57 Molar Flow, lbmole/h 4,104 4,104 Molar Flow, MMSCFD 37.4 37.4 Molar Flow, Nm3/h(gas) 41,728 41,728 Mass Density, lb/ft3 0.112 0.742 Molecular Weight 36.81 36.81 Composition, Mole Fraction Water 0.004209 0.004209 Hydrogen sulfide 0.000142 0.000142 Nitrogen 0.003173 0.003173 Carbon dioxide 0.733698 0.733698 Methane 0.254334 0.254334 Ethane 0.002551 0.002551 Propane 0.000244 0.000244 i-Butane 0.000068 0.000068 n-Butane 0.000034 0.000034 C5-C20 0.001544 0.001544

Note: pressure of 125psia is downstream the compressor after cooler Check case

UOP case 61 240MMscfd with PSA No depressurization step

PSA feed compressor

suction

PSA feed

Stream Name 12 16 Pressure, psia 17 125 Pressure, bar_g 0.2 7.9 Temperature, F 86 135 Temperature, C 30 57 Molar Flow, lbmole/h 3,709 3,709 Molar Flow, MMSCFD 33.8 33.8 Molar Flow, Nm3/h(gas) 37,710 37,710 Mass Density, lb/ft3 0.117 0.819 Molecular Weight 38.97 38.97 Composition, Mole Fraction Water 0.004657 0.004657 Hydrogen sulfide 0.000157 0.000157 Nitrogen 0.002235 0.002235 Carbon dioxide 0.811649 0.811649 Methane 0.178294 0.178294 Ethane 0.001344 0.001344 Propane 0.000055 0.000055 i-Butane 0.000005 0.000005 n-Butane 0.000002 0.000002 C5-C20 0.001532 0.001532

Note: pressure of 125psia is downstream the compressor after cooler




10.0 Close out of HAZOP report - FEED

PRELIMINARY HAZOP OUTSTANDING ITEMS FOR UOP DOC. NUM BER B060-ILFM-AD-0001-HAZOP STUDY POLYBED PSA Node 1: Feed Tie-in (PSA Feed)

Action item 1 : Review options for pressure control of product stream. A PIC on the PSA product line will be installed to maintain the PSA adsorption pressure.

closed

Action item 2 : Consider by-pass of PSA unit upstream of compressor FCV is installed to bypass compressor+PSA directly to incinerator to bypass excess feed flow. QO XV is installed to bypass compressor+PSA directly to cold vent.

closed

Action item 3 : PIC not available in existing plan PCV installed on compressor discharge and on PSA product line to cold flare.

closed

Action item 4 : PSV between compressor and PSA not installed yet PSV sized for full PSA feed flow installed on compressor discharge line downstream of discharge KO drum.

closed

Action item 5 : Consider position indicators for bypass valve As the FCV is a control valve, it will be equipped with a position transmitter internal in the valve positioner. SDV to be equipped with limit switches.

closed

Action item 6 : Check impact on MemGuard bed Upon trip of PSA compressor, the quick opening XV to cold vent will open and relief to cold vent. So there is no possibility to create significant pressure increase in the upstream system that could lift the MemGuard adsorber beds.

closed

Action item 7 : Shutdown system PSH/PSHH/ESD valves to be defined during basic engineering HH trips and ESD valve will be according to current plant philosophy.

closed

Action item 8 : Define location of piping class spec break All piping is 150 lbs class.

closed

Action item 9 : Impact (of PSV failure) on product gas composition to verified during basic engineering Expected variations in PSA product gas and PSA tail gas MW are negligible compared to the variations intrinsic to the normal PSA operation and addition of depressurisation gas. See basic engineering study 8.0. (Note: failure of PSV is failure of a safety device and not condidered in Hazop. Leakages through PSV are considered here, not failure)

closed

Action item 10/11 : TSHH not available TSHH installed on compressor discharge downstream of discharge KO drum. TSHH linked to PSA unit shutdown logic. Also TSHH on compressor discharge linked to compressor shutdown logic.

closed

Action item 12 : KO drum not yet available




KO drums installed on compressor suction and discharge.

closed

Action item 13 : PSA design to be reviewed in FEED study Addition of MemGuard depressurisation gas is included in the PSA design.

closed

Action item 14 : Corrosion of valves, erosion, to be defined during FEED study Preventive maintenance on PSA valves to be done per maintenance instructions. This includes regular valve seat replacement, tightening and/or replacement of gland packing in case of detection of valve leakages. Corrosion from H2S or CO2 is not expected as long as condensation does not occur. Feed and off-gas line are traced to prevent condensation. No condensation possible in product line.

closed

Action item 15 : SDVs and BDVs to be defined as per existing isolation concept BDVs installed on PSA adsorbers, to open on ESD-1.

closed

Node 2: Product Tie-in (PSA Product gas to recycle compressor)

Action item 1 : Review the anti-surge control system (of recycle compressor) Recycle compressor can handle sudden drop in feed flow by 12 MMSCFD, anti-surge valve may open.

closed

Action item 2 : Review the capacity of recycle compressor Recycle compressor can handle small reduction in feed flow due to lower recovery in 5-bed operation. Install flow measurement with high flow override to kick open PCV to cold vent.

closed

Action item 3 : Consider NRV and SDV SDV installed on PSA product line downstream of product PCV. NRV installed in between PCV and SDV on product line.

closed

Node 3: Tail Gas Tie-in (PSA Tail or Vent gas to Incinerator)

Action item 1 : Review requirement for PIC on tail gas in overall context with water seal pot on tail gas system PSV sized for full feed flow is installed. No need to install a water seal pot. PCV to cold vent is installed.

closed

Action item 2 : PSV design to be reviewed during basic / detailed design with respect to superimposed back pressure PSV is sized for full PSA feed gas flow to cover the scenario of a simultaneous failure of a feed and off-gas valve on the same adsorber within the PSA skid. PSV type shall depend on the ratio set pressure / superimposed back pressure to select pilot operated or balanced bellows type. OMV to recommend on maximum superimposed back pressure after detailed design of relief system has been done. See recommendation 14 of Hazop Feb 07.

closed

Action item 3 : Compatibility of PSA tail into incinerator gas to be reviewed by vendor Zeeco Design material balances will be supplied by UOP. Worst case scenario with 10% - 15% lower recovery will be included.

Out-standing




Node 4: Utilities

Action item 1 UOP to confirm O2 and CO2 content as well as dew-point of N2 used for purging 4% O2 content is rather high to reach below explosion limit values. Long purging may be required before levels below 5% O2 are reached. The plant can produce N2 of higher purity in O2 content at lower capacity; this would be preferable if it can be accommodated during PSA start-up if other unit demands allow for it. Dew point is rather high, water content may adsorb irreversibly onto PSA adsorbent and cause minor adsorbent deactivation. Dew-point of -40 C is recommended. It is confirmed by site that -40 C can be reached under optimum operating conditions.

To be included in operations manual

Action item 2 OMV operations to confirm availability of N2 Operations confirm during meeting of Feb 7th that the demand can be met.

Closed

Action item 3 OMV operations to confirm availability of Instrument air Operations confirm during meeting of Feb 7th that the demand can be met.

Closed

Action item 4 UOP to confirm electrical power consumption For PSA control cabinet including skid instrumentation and auxiliaries, 2 kW is sufficient. For tracing on feed and tail gas lines, approx 5 kW (to be confirmed) is required.

Closed

Action item 5 OMV operations to confirm availability of required electrical power Operations confirm during meeting of Feb 7th that the demand can be met.

Closed




MEMGUARD AFTERCOOLER UNIT Node 1:

Action 1 - Heat exchanger sizing to be addressed during basic engineering See section 3.0

closed

Action 2 Detail exchanger type and design to be defined during basic engineering See section 3.0 and detailed engineering phase

detailed engineering phase

Action 3 Review NRV locations during basic engineering NRVs have been reviewed during the HAZOP (section 11). Refer to PID in attachment 4.

closed

Action 4 Heat exchanger design to be addressed during basic engineering, fouling to be addressed properly See section 3.0, section 11 and detailed engineering phase. Replaced by Action 15 & 16 from the HAZOP meeting in Feb 2007.

Closed

Action 5 - Heat exchanger design to be addressed during basic engineering Same as action 2

Closed, Replaced by action 2

Action 6 Access and chemical cleaning requirements to be addressed during detailed engineering outstanding

detailed engineering phase

Action 7 Ops to review free cooling water capacity, system bottlenecks Outstanding, see data in section 3.0

By OMV

Action 8 CW demand to be defined during basic engineering See section 3.0

Closed

COSMAX UNIT Node 1: The COSMAX option is no longer considered by OMV Node 2: The COSMAX option is no longer considered by OMV Node 3: The COSMAX option is no longer considered by OMV




11.0 HAZOP report Basic Engineering

A HAZOP meeting was held on 6-7 February, attended by OMV engineering, operations & maintenance and UOP. The HAZOP report is attached in attachment 11. The PIDs are attached separately in Attachment 4 & 5 The action list is repeated below with a suggested responsibility for the next phase. The following responsibilities are considered 1. OMV (operations) 2. Detailed design 3. Compressor detailed design

Recommendations Place(s) Used Suggested Responsibility

1. provide level alarm in CCR in order to detect seal break Causes: 1.1.1 OMV

2. check pressure levels between inlet PSA compressor and tail gas outlet line PSA unit

Causes: 1.2.1 Detailed design

3. design compressor so that suction pressure will not go below 17 psia

Causes: 1.2.1 Compressor detailed design

4. compressor to shut down on failure of capacity control (high flow) Causes: 1.2.3 Detailed design

5. PSA compressor supplier to consider check valve at suction Causes: 1.4.2 Compressor detailed design

6. design compressor so that creation of vacuum due to compressor operation is not possible


7. PSA compressor should be capable to take into account the composition and MW variation


8. current philosophy of PCV to vent and FCV to incinerator is to be changed as it has been moved downstream PSA unit

Causes: 1.17.1 OMV

9. compressor aftercooler should be air cooler Causes: 2.15.4 Compressor detailed design

10. start-up procedure of PSA product should be integrated in recycle compressor turn-up procedure

Causes: 4.12.1 OMV

11. verify if incinerator will trip or go into safe mode operation upon FSLL

Causes: 5.1.1 OMV

12. verify if incinerator can cater slight variations in flow and composition

Causes: 5.2.1, 5.11.3

OMV

13. evaluate installation of check valves (opening of check valves in low pressure service)

Causes: 5.4.1 Detailed design

14. review of superimposed back pressure during basic / detail design Causes: 5.5.3 Detailed design

15. fouling to be addressed during detailed engineering Causes: 6.7.3 OMV

16. access and chemical cleaning requirements to be addressed during detailed engineering

Causes: 6.14.1 OMV

17. provision of corrosion coupons (CC) / probes Causes: 6.14.2 OMV

18. OMV to review available cooling water capacity, system bottlenecks

Causes: 6.15.1 OMV

19. evaluate selection procedure for PSV in order to avoid popping problems eg PSV seat material selection

Causes: 8.1.1 OMV




ATTACHMENT 1

Process Flow Diagram for Kadanwari Plant




ATTACHMENT 2

Block Diagram for Kadanwari Emission Overview




ATTACHMENT 3

Kadanwari

Recycle Compression System




ATTACHMENT 4 G6120-002/04

PID integration of MemGuard after coolers




ATTACHMENT 5 G6120-002/01 G6120-002/02 G6120-002/03

PID integration of PSA unit




ATTACHMENT 6 H2741-001 Proces Flow Diagram

PSA unit on Vent Gas




ATTACHMENT 7 H2741

Proposal for PSA unit on Vent Gas

Rev 1




ATTACHMENT 8 MemGuard after cooler design basis




ATTACHMENT 9

Solar proposal for PSA feed compressor with typical PIDs




ATTACHMENT 10

OMV Kadanwari PFD & PIDs




ATTACHMENT 11

HAZOP report

Documents

G6120 Basic Engineering _rev0