About

Early Production Facilities

SPETCO International’s contribution to the development of hydrocarbon reserves in Kuwait 

• The theory of an Early Production Facility in Kuwait was conceived to facilitate KOC to produce from the New Jurassic Reservoir. These reservoirs were first discovered in 1996 but KOC was unable to put them into production as the facilities in North Kuwait were not designed for sour services.
• This prompted SPETCO International to propose the concept of a modular Early Production Facility to KOC, which was accepted by KOC. As a result, the first pilot modular EPF in Kuwait was completed by SPETCO International in 2003.

EARLY PRODUCTION FACILITY FOR SA-153 (KOC)   

Pilot Early Production Facility (EPF) designed, engineered, installed, commissioned, operated & maintained by SPETCO for processing and testing of sour crude and gas from a new light oil discovery in North Kuwait. The facility strips the H2S in the inlet crude and gas and transfers the sweet products to KOC GC-23 

SCOPE OF WORK  

• Design, Engineering, Supply, Installation, Commissioning, Operations and Maintenance of an Early Production Facility (EPF) for KOC for treating of sour crude and gas to remove the H2S and transfer the sweet products to KOC Gathering Centre.  
• This facility comprised of 2 stages of separators, Amine Contactors, Amine Still column for DGA regeneration, Fuel gas powered Hot Oil media Heater, Crude Oil Stabilizer tower, Flare system, Thermal Oxidizer for incineration of H2S, Chilled Water Unit, etc. 
• Design, Engineering and construction of approximately 17 kms of flowline and product lines of 4”, 6” and 8” on a turnkey basis. 
• Simulations of process using PRO 11 process simulation software. 
• Reduction of the H2S concentration in the treated crude down to less than 70 ppm and treated sweet gas to less than 4 ppm from the inlet stream H2S concentration of 10,000 ppm 

• Maintenance of independent power generation units for the facility operations. 
• Operate the EPF to deliver the crude & gas to the specifications required by KOC. 

HIGHLIGHTS:  

• Uptime of 100%. 
• NO ACCIDENTS from start of construction through operation – 32 months 

• Completed 400,000 man-hours at the EPF without any LTA. 
• Processed & Exported Approx 3.2 Million BBLS of Sweet Crude & 9 Billion scf of Sweet Gas till completion of contract.  
• Recognition by KOC C&MD and the Management for SPETCO’s contribution to realization of KOC’s Long Term Test Goals & Objectives. 

50 MBOPD EPF FOR NORTH KUWAIT JURASSIC PRODUCTION   

Early Production Facility (EPF) located at North Kuwait, for processing sour crude from 20 oil wells in Sabriyah, Bahra, Raudhatain and NW Raudhatain oil fields, including all related pipe and flow lines and associated works.  This facility has a capacity of 50 MBOPD stabilized, dehydrated crude, 175 MMSCFD of sweetened gas & 136 TPD of molten sulfur. 

SCOPE OF WORK  

• Design, Engineering, Supply, Installation, Commissioning, Operations and Maintenance of an Early Production Facility (EPF) for KOC for treating of sour crude and gas to remove the H2S and transfer the sweet products to KOC Gathering Centre.  
• Light sour crude of API 44 to 46 from 24 Production wells from a deep Jurassic reservoir to produce to this facility. H2S upto 20,000 ppm. 
• Design, Engineering and construction of approximately 330 kms of 6” flowline and 12 kms Export Pipeline.  

• 50,000 bbl/day Sweet Crude Export, 175 mmscfd Sweet Dehydrated Gas Export & 135 TPD Sulfur Recovery Unit 
• Detailed engineering of the EPF and all associated facilities. 
• Equipment Fabrication & Manufacturing, Site Construction & commissioning of EPF & related facilities. 
• Operate the EPF to deliver the crude & gas to specifications required by KOC. 
• Maintenance of EPF 

40 MBOPD JPF-3 FOR NORTH KUWAIT JURASSIC PRODUCTION

Project Scope comprises of design, engineering, fabrication, installation, testing, pre-commissioning, commissioning, O&M of Jurassic Production Facility (JPF) with a capacity of processing 40 STMBOPD Oil and 104 MMSCFD Gas & 200 TPD of molten sulphur in North Kuwait comprising of the following major process systems: 

• Crude Oil Processing 

• Gas/Oil Separation Plant 
• Crude Dehydration & Desalting Plant 
• Crude Stabilization Plant 
• Stabilized Crude Measurement & Export System 

• Gas Compression Plant 
• Gas Sweetening Plant 
• Gas Dehydration Plant 

• Vapor Recovery Units 
• Gas Metering & Export System 
• Plant Refrigeration 
• Closed Drain and Open Drain System 
• Fire Water System 

• Sulphur Recovery Unit including storage, degassing & loading facilities 
• Tail Gas Treating Plant 
• Incineration & Flare System 
• Raw Water Treating Plant 
• Effluent Water Treatment Plant 

• Effluent Water Disposal Systems 
• Chemical Injection Systems 
• Steam Systems- Heat Recovery Steam Generators & WH Boilers 
• Electrical Power Generation Plant 
• Plant Control & Safety Systems 

• Data Communication System 
• Control Room, MCC Building, Workshops 
• Other Supporting Utilities 

UPGRADE OF JPF-3 FOR NORTH KUWAIT JURRASIC PRODUCTION

Project scope comprised of Upgrade of the Oil Treatment System & Gas Treatment System of JPF to increase production capacity of Gas from 104 mmscfd to 150 mmscfd and Oil from 40 MBOPD to 50 MBOPD.

50 MBOPD JPF-4 FOR NORTH KUWAIT JURRASSIC PRODUCTION – CONSTRUCTION IN PROGRESS

Project Scope comprises of design, engineering, fabrication, installation, testing, pre-commissioning, commissioning, O&M of Jurassic Production Facility (JPF) with a capacity of processing 50 STMBOPD Oil and 150 MMSCFD Gas & 240 TPD of molten sulphur in North Kuwait comprising of the following major process systems:

• Crude Oil Processing
  • Gas/Oil Separation Plant
  • Crude Dehydration & Desalting Plant
  • Crude Stabilization Plant
  • Stabilized Crude Measurement & Export System
• Gas Compression Plant
• Gas Sweetening Plant
• Gas Dehydration Plant
• Vapor Recovery Units
• Gas Metering & Export System
• Plant Refrigeration
• Fire Water System
• Sulphur Recovery Unit
• Tail Gas Treating Plant
• Incineration & Flare System
• Raw Water Treating Plant
• Effluent Water Treatment Plant & Disposal Systems
• Chemical Injection Systems
• Steam Systems- Heat Recovery Steam Generators & WH Boilers
• Electrical Power Generation Plant
• Plant Control & Safety Systems
• Data Communication System
• Control Room, MCC Building, Workshops
• Other Supporting Utilities