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50 MBOPD EPF for North Kuwait Jurassic Production

SPETCO International developed the 50 mbopd capacity Early Production Facility (EPF) in North Kuwait. Currently, the facility processes sour crude from 20 oil wells in Sabriyah, Bahra, Raudhatain and the NW Raudhatain oil fields of KOC, including all related pipe and flow lines and associated works.

This facility is designed for processing and exporting 175 mmscfd gas and 50,000 bpd condensate and 136 TPD of molten sulfur from the 20 wells with 30,000 ppm H2S in the inlet feed.

Project Timeline:

  • Stage I – Facility design, engineering, construction and commissioning completed in 25 months.
  • Stage II – Facility 60-month operations and maintenance commenced in March 2009.

Facility Details:

Hydrocarbon Inlet and GOSP

  • 3 stages of separation in two trains (dry and wet). High Pressure (HP) 1150 psi, Medium Pressure (MP) 450 and Low Pressure (LP) 125 psi.
  • Gas stream from the HP Separator continues to the HP Trim Cooler and HP sour filter/separator.
  • MP and LP gas streams continue to the respective stages of the compressor suction and the crude is fed to the desalter and subsequently the Condensate Stabilizer.

Condensate Stabilization Column

  • Condensate is heated and stabilized in the stabilization tower to remove acid gases and control the RVP in the export crude.
  • The H2S in the crude is reduced to less that 10 ppm while maintaining the RVP at 9 psia. This is achieved by feeding the crude oil to the top tray (28 Total Trays).

      Operational parameters of this column are:

       • Capacity: 50,000 BPD
       • Pressure: 60 psig
       • Top Temperature: 105 °F
       • Bottom Temperature: 225 °F.

Desalting and Dehydration

  • Two Desalter Trains at the EPF-50, each train consists of two stages with a design rate of 12,500 BOPD per train.
  • BS&W and salts in the inlet feed are reduced to less than 0.1% BS&W and 5 PTB salt in the outlet crude.

Gas Processing (Sweetening and Dehydration Units)

  • Gas from the various stages of the separation is compressed to the HP gas pressure and treated in an Amine System using MDEA as the solvent, to remove the acid gases like H2S and CO2.
  • As treated gas leaves the amine contactor, it is free of H2S and then proceeds to the Glycol Dehydration Unit (TEG unit) for dehydration and water dew point control; this gas is then fed to the main gas export line.

Sulphur Recovery Unit

  • H2S is removed from the natural gas and processed through a 2-stage Claus Sulphur Recovery unit to convert the H2S to elemental sulphur; capacity of the SRU is 135 LTPD.
  • The SRU features two trains (dry and wet) to recover approximately 96% of the sulphur.
  • The plant is also equipped with a Tail Gas Unit (TGU) to further remove the sulphur compounds and increase sulfur recovery efficiency to 99.8%.

Utilities

  • Electricity for the operations of the facility is provided by four Solar Gas Turbine Generators. Two of the gas turbines are fitted with waste heat recovery steam generators, which produce steam. This steam is used for reboilers, pre-heaters, and other heating needs across the plant.
  • Water is produced from source water wells and treated using RO units to obtain boiler quality water.
  • The effluent water is treated to less than 10 ppm oil in water content and disposed downhole.

Flowlines

  • 330 kms of inlet flowlines to the facility (20 wells).
  • 7 kms of 10” crude and 16”gas product line.

Highlights

NO ACCIDENTS from start of construction through operation – 36 months.