GOS Gas Plant.

Presentation for G.O.S Gas

Gathering Plant

Eng. :Aly Abdullah Salah

N J&R FIELD
Gulf of Suez
Saqqara Sedki
October
M1 ESMA-2&8

M-36 GL Badri
Shoab Ali Helal
M-1

CURRENT FLOW
26 MMSCFD
U-103
MAX. U-102
8’’ BSUL MAX.
54 MMSCFD
T.G 60 MMSCFD

CURRENT 105-110 U-108 16’’

CURRENT FLOW

MAX. 135 MMSCFD CURRENT FLOW Saqqara 3 MMSCFD

20 MMSCFD 16’’ MAX. MAX. 20’’
60 144 MMSCFD
16’’ MMSCFD
ASHRAFI&OAPCO
CURRENT FLOW MAX.30MMSCFD
42 MMSCFD
16’’
16’’ AMAL
MAX.
16’’ NEW TIE-IN 80 MMSCFD
16’’

16’’
U-104 8’’
CURRENT 80-100
MAX. 170 MMSCFD
SUCO
SALES GAS TO GASCO MAX.
CURRENT FLOW 16’’ 70 MMSCFD
EBGDCO 16’’ NEW TIE-IN 20 MMSCFD
Min.
50 MMSCFD
Proposed mode of
operation in RED color

GOS GAS DIST. FLOW DIAGRAM

 C/F 5 MMSCFD
U102 & Max. 72 MMSCFD
AGIBA
C/F 5 MMSCFD
U103
Max. 60 MMSCFD

C/F 30 MMSCFD
U108
Max. 144 MMSCFD

8``
AMAL Feed Gas Inlet Separator Main Compression Area
C/F 70 MMSCFD 16`` Drying & Sweetening Area
4 Units, Max. Capacity 220 MMSCFD
6 Molecular Sieves beds, Type 5A
plant pressure 49 kg/cm2
Diethanolamine Unit
C/F 60 MMSCFD
SUCO REMOVE H2S & H2O
Max. 70 MMSCFD

Sales Gas to GASCO

Booster & Sales Gas Compressors

6 Units, Max Capacity 210 MMSCFD
FOR BOOSITING SALES GAS TO Chilling Area
THE NATIONAL GRID Turbo-Expanders
4 Units Gas/Gas Heat Exchangers
PH I (-54 C) Gas/Liquid Heat Exchangers
PH II(-80 C) { -25C}
LPG Spheres
CONDENSING THE CONDENSATE
5 Spheres, 6,000 ton Capacity
AND LPG

Condensates Tanks
2 Floating Roof Tanks
Fractionation Area
U104 Flow Diagram
FOR SPLITING CONDENSATE
Capacity 38,000 bbl AND LPG
Plant Design Data:

• U-104 Gas Plant consists of two phases, phase-I was

first established on 1983, while phase-II opening was
in 1987.
• Gas plant receives its feed gas from satellite stations
(U-102, U-103, U-108 and SAQQARA) and sister
companies (AMAL and SUCO).
• Plant is designed for processing 170 mmscfd of feed
gas (Maximum 220 mmscfd).
• Current average feed gas is 170-180 mmscfd.
Plant Products:
LPG:
• Current average production is 550 tons/day.

• Plant is designed to recover minimum 94% of the

butane in the feed as LPG product.

• LPG Storage Capacity:

two spherical tanks ( 2000 tons each)

three spherical tanks (600 tons each)

Plant Products:
2) Sales Gas:
• Plant is deigned to produce 160 mmscfd.

• Current average production is 150-160 mmscfd.

• Part of the produced sales gas serves as fuel gas for

GOS turbines stations, while another part is used in
gas lift for off shore stations.
Plant Products:
3) Condensate:
• Current average production is 1150 bbl./day.

• Condensate Storage Capacity:

I. Ph- I Floating Roof Tank = 11.05 M (17975 bbl.)

II. Ph-II Floating Roof Tank = 11.97 M (19646 bbl)

THE INLET AREA
 suco
Deh-U 108
SDV-1955B
SDV1903

Amal 8”

SDV1955A
Amal 16”

U-108

U-101
8-ESD 711

Header pipe
SDV 1952 U-102+SUCO

U-103

SDV1950

To Filed Gas Separator

 Block Diagram For U-104 , U-102 , SUCO
and EBGDCO Current mode of operation

CURRENT Measured
16’’ P/L
FLOW GASCO 16”
U-102 by Suco is 70 MMSCFD U-104
MAX. CURRENT
80 MMSCFD MAX. 170 MMSCFD

14’’ P/L
CURRENT FLOW
160 MMSCFD

Flow computer FT-105

@ Suco Site
SUCO EBGDCO
MAX.
70 MMSCFD

FT

10’’ P/L
10’’ P/L
Flow computer FT-200

@ U104 Site
 100 mmscfd GASCO
JULY 10 FUEL GAS
( SALES Gas for T/G 3 MMSCFD
0.8 mmscfd ( U103 Fuel Gas) )

6 mmscfd ( R/SH FACILITIES)

6 mmscfd Morgan gas
Forecasted Gas Flow Rates lift

For U-104 & EBGDCO NGL 2.5 mmscfd Morgan water flood

Plant 20 MMSCFDSuco Gas Lift FUEL U-104 : 18 MMSCFD

Compressors 153 mmscfd
( Residue Gas )

190Ton/d propane
Sales To EBGDCO

U-102 FUEL GAS 1MMSCFD Gas Plant ( U-104 ) 160 MMSCFD EBGDCO 5 Ton/d Butane
170 MMSCFD
U-103 TO T/G 5 MMSCFD

SUCO GAS TO T/G 15 MMSCFD

SUCO 60
MMSCFD
SHRINKAGE GAS : 10 MMSCFD
Amal 70 MMSCFD 190 MMSCFD

Gupco 60 MMSCFD

U-108.40 U-102.7 U-103.7 SAQQ.6

• THE SEPARATION AREA
 The Main Separators Used in U-104

• Aim of inlet separators 4-V101 &4-V1 is to

separate the inlet steam to 3 phases "Gas
,water & condensate by using the
gravitational force mainly.
The Designed Operating Conditions Of
4V1,4V101.

Vessels P kg/m2 T C0 Q MMSCFD

4-V1 Min 6,Max 7 Max 38 80

4-V101 Min 6,Max 7 Max 38 90

 Control of V1 and V101:

2PIC 301

Signal (3-15) psig

Signal (3-9) psig Signal 9-15) psig

INCREASE THE TURBINE SPEED

2 SIC-1001 2PV-301 TO FLARE

LIC 701 and 702: a liquid level controller indicates the height of liquid
level inside the vessel and controls it according to the operating variables.
 Flare Line

From V109
Suc.Booster
LPG Tanks

2pv301

4-HV1104
HV 1108
V109 liquid 4v-102A
PSV
1903A
From T.c.u
ESD-1901 4V-102B

1903B
2SDV 1902 fl

Mist Extractor
Baffle 4
4v1
TO Main ph 1
weir
4V-101
OIL Start up fuel
condensate
H2O

Water

2lv-701
2lic 702

Lablare tank

CD Suction 8-v80
 Flare Line

Suc.Booster 1960B

tcu

HIC 1102
V-109 1961B
OFF SPEC LPG

-
PSV 4-W1A
PSV

ESD-1954
PV301
1960A

ESD-1953 4-W1B

1961A

To Main
ph 2
Man Hole
Mist Extractor 4-V101
Baffle
T.C.U
From 4-V15
weir
4V1 FLARE

Condensate
condensate Start up fuel
H2O

U-108
4-T I Water
flare
2LV-4001
Lv-700
Flare

C.D

O.D
T.C.U 4V201

U-108

O.D Lablar Tank

• Compression Area
 Compression Area
• The associated gases are compressed to the
suitable pressure for the L.P.G Recovery process by
two parallel Main Compressors.4-C1 A/B, 4-C101
A/B.
• The Compressors are designed to operate at each
50% 0f the expansion unit feed.
• a maximum capacity of 75% when one of the
existing main compressors stopped.
The Operating Condition Of Main Compressor PH I,II
Main Compression Suction. Main Compression Discharge.
Process

1st Stage. 2nd Stage 1st Stage. 2nd stage.

P kg/cm2 6 18 18 46

T C0 20 103 32 129

Main Compression Suction. Main Compression Discharge.

Process

1st Stage. 2nd Stage 1st Stage. 2nd stage.

P kg/cm2 6 18 18 50

T C0 20 112.5 29.5 115

 The Difference Between Ph I &II

• Cooling in phase-I take place through water coolers "either

in inter stage cooling or after cooling .

• Cooling in phase II inter stage cooling take place in air

cooler but in after cooling case gas is cooled by air cooler
followed by water cooler.
 Gas to 4-V104 A/B

4 - E2 A
SDV 1963A

Gas to Dehydration
Phase I
4 - E1 A Flare
Train A
SDV 1962A Gas from
4-W1A 4-C1A 4-C1B

FIC
101A Condensate from 4-V2B

LV 732A
To 4-P57 Discharge

4-V4 2SDV 1941

SDV 1961A 4-V2 4-V3
From 4-P57 Discharge

SDV 1960A Condensate to 4-T1

4-P57A 4-P57C 4-P57B
Gas from 4-V101
2FV
LV
105
708A
LV 706A LV
2FV
CD 732B CD To T.C.U
191B

CD 4- V 3A
4- V4A
4- V2A Set at59 Kg/Cm2
Set at 6.8 Kg/Cm2 Set at 20 Kg/Cm2 To 4-V3B liq. Outlet line
 Gas from 4-V4 A/B

2SDV 1905A
2SDV 1942A 4-A102A

Flare
Gas to Dehydration
Phase II 2SDV 1906A
Train A 4-A101A 4-E102A Gas from 4-C101B
Flare
4-W101A 4-C101A
Condensate from 4-V102B
2FV
103A
From 4-P57 Discharge
2-LV
703A
4-V102

4-V103
To 4-P57 Discharge

4-V104
2SDV 1903A
2SDV 1941

2SDV 1904A Condensate to 4-T101

4-P157A 4-P157C 4-P157B
Gas from 4-V101
2FV 105
2-LV 708A

2-LV 706A
2FV 181A 2-LV 703B To T.C.U

CD 4-V104A
4-V102A 4-V103A
Set at 20 Kg/Cm2 To 4-V103B Set at59 Kg/Cm2
Set at 8 Kg/Cm2
liq. Outlet line
• Drying Area
 Drying Area
• N.G comes from main compression area (V4,V104
A/B) into inlet separators V43,V143 in every
phase from which condensed H.Cs leave from
bottom back to V1,V101, from the top N.Gas leaves
to a three beds of molecular sieve in every
phase(D1 , D101 - A,B,C ) - In parallel .
• N .Gas inter the beds from the top against its
nature-down stream the beds- for more contact
with M.S beds .
 Drying Area
• After adsorption of H2O,H2S on M. Sieve sweet
gas leaves the bottom of beds to dust filter
(F17,F117) which filter it molecular sieve dusts
resulted from corrosion .
• Apart of sweet gas taken for regeneration of beds,
the other go to chilling area .
 Regeneration
• This stage is done by a fraction of dried, sweetened
gas
( 23-26 MMSCFD ) taken from F17,F117 to C5A/B ( to
drive the Reg. Gas in the Reg. cycle )after that to M.S bed
under cooling.
 Regeneration Gas Conditions
• Heating Reg. Gas inter M.S beds from its bottom
at about 300C and leaves at less than 240 C.

• Cooling Reg. Gas inter M.S beds from its top at

about 43C and leaves at about 65C degrees.
 Fv-4004
Drawn byEng :Aly Salah

MDV4001
4-C1A\B

4003

4005
4-V43
4-E3 RDV4007
FV-108 4009 4011
Lv-4001

flare
4-D1A 4-D1B 4-D1C

FV-4005 TO BY PASS HEATER

FV-4020
C.D

FV-4003
FV-4011

MDV4002
Amine

4012
4004

4006
4-f17

4008

4010
unit 4C3
FV-4006

FV-4015

4-V15 FV-4002 TO BY PASS COOLING

FV-4007 C5A/B
FV-4019 FV-4001

FV-4017
4005
4009

4003
4007

fl
4001

4011
BDV4001
2FV-4012

4-H1D

2FV-217
4-V143 4-D101B C103
D101A D101B D101C

4-C101A\B FV-107 ESD1908 FL

2lic4001

FV-4018
FL
4002

ESD1907
4004
4008

4006

4012 2F117

CD DBB
Amine Unit
 Process Description
• Cooled and scrubbed gas from 4-V15 enters the
amine contactor and also lean amine is
pumped from the top tray to remove sour
components.

• The amount of sour components in the

sweetened gas varies between no sour (Nill
ppm) and about 15 mol % of sour components.
 Process Description
• After sweetening in amine contactor 4-T4 the
sweet gas enters 4-V37 before being re-fed to the
plant.
• The rich amine solution after being filtered and
exchanged enters the amine still 4-T5 in which
removal of sour components take place and flared
and the lean amine solution is recirculated in the
operation again.
 Di ethanolamine System
DEA is a secondary amine that has in recent years replaced MEA
as the most common chemical solvent. As a secondary
amine.DEA is weaker base than MEA. And therefore DEA
systems do not typically suffer the same corrosion
problems.in addition.DEA has lower vapor loss. Requires less
heat for regeneration per mole of acid gas removed. And
does not require a declaimer .DEA reacts with H2S and CO2 as
follow:-
Low temp
2R2NH + H2S (R2NH)2S +H2S 2R2NH2SH.
Hi.Temp.

2R2NH +CO2 R2NCOONH2R2.

 Solvent MEA DEA

Chemical Formula RNH2 R2NH

Molecular weight 61 105

Amine type Primary Secondary

vapor pressure (100 F) 1.05 0.058

Freezing point (F) 15 20

Solution weight (%) 20 30

Loading (mole AG/mole amine) 0.35 0.5

Reboiler Temp, 240 245

 Pv-4001

.
Acid fla
flare PV-4027

Vacuum breaker purge fuel Gas

LEAN DEA to 4-v43

4-E23
4-E24
Fv-4002
4-P46A/B To acid flare

Lv-4008
4-V37
Re Amine

V39
Lv-4005 4-v40
Skimmer 4-v38
4-f18 water
4-P47A/B

4-p49
LV-4006 4-E25
SOUR GAS
Lv-4004 4-f19

4-T4 LV-4007 STR. 4-T5

FV-4006

TO FLARE LIQUID HC
4-H9
FV-4007
INLET DRYERS

Fv-4009

4-V15 V-37 BDV 4004

4-v1
SUMP TANK

4-P48A/B
Lv 4003
t.c.u
Fv-4008 To Sump Tank
• Gas Cooling and Expansion
 • Gas Cooling and Expansion
• The sweet gas from molecular sieve unit are chilled in heat
exchangers and turbo expanders to separate the butane
component in the H.C liquid.
• At Phase II:
• Plant feed gas is lean: Low pressure gas from 4-V108A/B is
increased; Increase flow rate to 4-E104 A/B by closing
2HV-1102 A/B.
• Plant feed gas is Rich: High pressure gas from 4-V107A/B
is increased; Increase flow rate into 4-E105A/B by opening
2HV-1102 A/B.
• It is important to maintain minimum temp. at 4-V107A/B
and 4-V7 A/B to obtain a good butane recovery rate.
 Control of Chilling Area:
• Flow controller in the expander bypass line (J.T valve) is
activated automatically in case the expander is shut down
by one of its safe guard's circuits; and also 2SDV valve on
the recompressor by-pass line and the PCV on the outlet
line of the L.P separator are opened automatically to flow
the lean gas toward booster compressor.
• Anti-Surge recycle control system is provided on
expander/compressor. If the compressor operation point
approaches the surge limit, the discharge gas will be
recycled to the suction.
 Gas Cooling and Expansion
The Difference between PH-I I& PH-II:
• Cooling gas in phase I takes place through Heat
Exchangers in series while in phase II cooling gas
takes place in Heat Exchangers in parallel.

• No.of H.E. In ph I =6 while in ph II =5 for every train

• Seal gas for expanders PH-I is from dryers (PV-364);

for PH-II is from boosters (4-V16 A/B/C and 4-V116
A/B).
 SDV-1910
From Dryers
PV-
315A/B

Recomp.bypass
4-E104A1

4-E104A2 4-E106

4-V-107A/B
HV 1101A/B

FV-109A/B
4-
4-V109

SDV 1915A/B
HV-1103A/B

fv114A/B
CF
FL

SDV-1917
SDV-1913
E105A1/B1 SDV-1918
SDV-1914

SDV-1912

4-V108A/B
HV1102A/B
E105A2/B2
.
Main Feed to Depropanizer
FV-112A/B

Booster Suction

4-T101

LV-712A/B

4-P112A/B/C
• FRACTIONATION AREA
 FRACTIONATION AREA

• The main task of this area is to remove

excess propane and lighter components
from the recovered hydrocarbon liquids in
the depropanizer, And to fractionate
depropanizer bottom into LPG & naphtha in
the Debutanizer.
 FRACTIONATION AREA
• In PH-I Depropanizer overhead condensers 4-E9
A/B are presently cooled by the cooled expander
vapor, In addition to this the refrigeration package
is used to supply the required refrigerant, which
lead to:
1) Better fractionation in PH-I depropanizer.
2) More available cooling to the incoming gas in the
chilling train.
3) Inc. in butane recovery.
 FRACTIONATION AREA
Vapor Pressure of LPG product is dependent upon the
butane/propane ratio at 4-T101 depropanizer bottom :
1) If the V.P is low; increase the reflux flow rate, then the
propane component in the bottom product of 4-T101 is
increased. The hot oil flow rate is automatically increased by
2TIC-517 for keeping the Reboiler temp. Constant.
2) If the V.P is high; decrease the reflux flow rate, then the
propane component in the bottom product of 4-T101 is
decreased.
3) If C5+ are increased in LPG; increase reflux flow rate in the
debutanizer.
The main differences between two
phases:
1) In 4-T1 the top product cooling exchanger
4-E9A/Doesn't exist in 4-T101 whish use propane
refrigerant exchanger.
2) In phase I bottom product of 4-T1 is used to cool
bottom product of 4-T2, by E11 which is not exist
in phase II. But cooling of naphtha is done only by
4-E114.
 2-HIC 1107 T0 4-E104 S/S

Methanol point 2-PIC 324

4-T101
4
LOW PRESS.LIQ.
4-E109
B 2PIC-323

TOTAL COND.UNIT 2-lv717

Propane Refrigeration
FL
4
4-E105A/B-HI PRES.
A

4
4-E5 A/B.HI PRESS.

4-V109

Heating Oil Supply 4-P105

4
HeatinReturng Oil
4-E110
2TV517
2-lv716
2-FIC 123 Feed to Debutanizer
BOOSTING AREA
 BOOSTING AREA
1) The lean gas leaving the recompressor is boosted
to obtain the pressure needed for the sales gas line;
this operation takes place in the booster
compressors.
2) Five parallel, two stage compressors (4C104A, B-
4C4A, B, C) equipped by separators and coolers.
3) Compressors are driven by gas turbines.
4) Compressor speed is controlled by pressure
controller on suction line PIC 317.
 Control of Booster compressor:
1) The compressor speed is controlled by pressure
controller (PIC-317& 2PIC-317) in the suction line in this
way the delivered gas is compressed and the suction
pressure is maintained constant, if the gas is supplied
over the capacity of the compressor, it automatically
vented to flare.
2) Each compressor has an anti-surge loop to prevent
surging, a minimum flow is taken from the out of 4-A8&
4-A108 to recycle back to the inlet of first stage of the
compressor through a control valve connected with the
compressor to prevent the compressor from dropping
under the designed inlet safe flow.
 The Difference between phase-I &
phase-II:
1) The inter cooler in phase I take place through water
coolers while in phase II inter stage cooling take place in
air cooler .
2) There are 3 compressors in PH-I and 2 compressors in
PH-II.
 FUEL GAS OF TURBO-STARTER

PI-316C
57.2 kg/cm2
FUEL GAS

E8A
TI-24C 2TI-25C
98 C 53 C
M
PZ-317C PZ-317C
81 % 4-C4A

TI-23C
FI-106A 39 C
48 mmscfd

TI-22C FV-106A
PI-315C 100 C
30.2 kg/cm2
LEAN GAS
C3A/B CW CW C4C
DSCHRG
C104A/B
SUC
E7A

V16A LV-733A

BD