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Gas Compression and Re-Injection Facility

KOC has commissioned SPETCO International to design, build, test, commission, operate and maintain a Gas Compression Package (GCP) near GC-28 at TP-4 using the gas from GC 16 & 28 and Gas Re-Injection Package (GRIP) near wells MN 129 and MN 140. In line with the Kuwait Oil Company’s objective of achieving zero flaring, the project is intended to increase the gas export capability and reduce gas and condensate flaring in the Gathering Center 16 (GC-16).

The system is broadly comprised of compressor stations, interconnecting pipelines, a data acquisition system and a dedicated optical fibre cable based telecommunication system. All related and associated systems required for operation and control of the system will also be provided. These include emergency shutdown system, process measurement and control instrumentation, fire alarm and fire protection system, power system, utilities such as instrument air, nitrogen, fuel gas, flare & burn pit, fire & brackish water, chemical injection, diesel handling.

TV Compressor Package

The GCP TV Compressor package compresses 6 mmscfd TV gas sourced from GC-16 Crude Tank at operating pressure of 5’’ WG and transfer the discharged gas through a LP gas transfer line at 60-70 psig to GCP LP Compressor package at TP-4. The TV Compressor package at GC-16 is located close to GC-16. To protect the Crude Tank from vacuum conditions, automatic pressure maintenance recycle from GC-16 LP gas is provided to automatically compensate for any deficiency in suction pressure at the TV compressor suction header. A suction scrubber is provided for safe operation of the compressor package at all operating conditions, taking into account possible condensate formation in the source gas, particularly during winter.

Liquid collected in the TV suction scrubber, which is in compressor vendor scope, is drained to the (blow case) Egg Barrel and lifted suitably by gas pressurization to the closed drain header. PSV discharges are connected to the LP/HP Flare at GC-16. A pressure equalizing line is provided to maintain the pressure of the TV compressor suction scrubber to facilitate liquid draining from scrubber to Egg Barrel.

The gas is compressed through a two-stage reciprocating compressor. Auto bypass, auto blow down and blow down valves are provided for the compressor unit to maximize safety. Air Coolers are provided for both interstage and discharge cooling. Two fans driven by an electric motor are employed for the air coolers.

Gas Compression Package (GCP)

  • LP Compressor Package

Source of LP gas is either from GC-16 (LP+TV) or from GC-28 (from LP Separator KO Drum). The LP gas transfer line carrying the LP+TV of GC-16 is routed to a new LP Gas Inlet Manifold, near TP-4 with pigging facilities to absorb the slamming actions of liquid slug, etc. at either end of the pipeline (namely in the vicinity of GC-16 and TP-4). The pig receiver and all other reliefs including common LP scrubber relief shall be integrated into the flare header of the GCP. The LP pig launcher relief goes to the existing flare in GC-16.

The Common LP Scrubber is designed for handling liquid slug during pigging and normal operation. The scrubber is provided with automatic level control valves and collected liquids are routed to the LP Compressor Closed Drain Header.

The GCP LP Compressor compresses the incoming gas from 20-60 psig to 270-300 psig and transfers the discharged gas to a 30” HP compressor suction manifold. The gas is compressed through a three-stage reciprocating compressor.

  • HP Compressor Package

HP Gas from GC-16 is branched off through a new HP Scrubber to a new HP gas transfer line (approximate distance 3.5 KM) between GC-16 and TP-4 near GC-28. The line is equipped with pigging facility. HP gas may also come from the GC-28 HP Separator KO Drum.

All sources of HP gas join in a Common HP manifold before going to the Common HP Scrubber. The HP Common Scrubber is provided with automatic level control valves and collected liquids are routed to the HP Compressor Closed Drain Header. HP Gas is routed to the HP Gas Suction Scrubber within the compressor package. The GCP HP Compressor compresses the incoming gas from suction pressure of 210-260 psig to discharge pressure of 900-1,000 psig. The gas is compressed through a three-stage reciprocating compressor.

Gas Re-Injection Package (GRIP)

GRIP is comprised of four Compressor packages (15 mmscfd ), two compressor package units cater to each of the two gas re-injection wells MN129 and 140 in Minagish field with cross-over facilities.

The Gas Re-Injection Packages are designed to compress wet and dehydrated gas from GCP discharge and AGRP-MAA 18” export gas network. The feed gas from the 24” GRIP Feed Gas Manifold shall be routed to the New Slug Catcher through a 16” pipeline (feed gas line). The source of GRIP gas is either from the GCP HP Compressor or from the 18” gas export line from GC-28.

The GRIP Compressor compresses the incoming gas from suction pressure of 700-1,000 psig to discharge pressure of 4,000-4,500 psig.

Gas from the after-cooler is routed to the GRIP Compressor Discharge Scrubber. The discharged gas is routed to two Compressor Discharge Headers which are interconnected so that the gas can be fed to Gas Re-Injection Wells MN 129 and MN 140. Condensate from the discharge scrubber is routed to the GRIP Condensate Transfer Manifold.