Project Profile
Value: Undisclosed
Location: North Kuwait
Processing capacity: 175 MMscfd of sour gas and 50 Mbopd of crude
Start-up Year: -
Kuwait Oil Company started free gas production from its Jurassic sour gas field in May 2008 with the commissioning of Early Production Facility EPF-50. The field produces sour gas and light crude (API: 48) from a deep High Pressure High Temperature naturally fractured carbonate reservoir of low permeability and low porosity. The formation pressure and temperature are in the range of 10,000 psi and 275 deg. The well fluid is characterised by high H2S (5%) and CO2 content (5%). 26 wells are presently connected to EPF-50. The field is planned to be developed in 3 phases. Early Production Facility-50 is part of the 1st phase of development of the Jurassic Gas field. Work is presently on-going for Phase-II and is expected to be on-stream by 2013. By 2015 it is expected that phase-III will be rolled out and peak gas production will be achieved from this field.
Early Production facility-50 has been designed to process 175 MMscfd of sour gas and 50 Mbopd of crude to pipeline specifications. The export crude specifications being monitored for the facility is H2S in crude (11 ppm max.) BS&W (0.1% max.) Salt (21 PTB max.) RVP (10 psia max.) and API. For export gas, pipeline specifications is H2S (11 ppm max.) and Moisture (8 lbs/MMscf). There are 2 trains for processing of the Jurassic well fluid in EPF-50, the Dry and the Wet train. The dry train has been designed to process 175 MMscfd gas and 50 Mbopd crude. The wet train is designed for 70 MMscfd and 20Mbopd. Design margin considered has been 20% for gas, 15% for crude and 25% for water. A test header has been provided to test wells inside the facility, apart from regular field testing. 3 wells are tested on a daily basis at the facility using a multiphase Vx meter. Separation is done in 3 stages with the bulk of gas being released in the HP dry separator. The gas separating out in the MP and LP seperators are compressed before being treated, along with the HP gas, in the Amine unit. After sweetening, the gas is dehydrated to meet pipeline specifications and sent to the downstream refinery unit.
The acid gas generated in the Amine units is converted to sulphur using the Clause Process in 2 nos. of SRU’s provided in the facility. Molten sulphur produced is transported to the downstream refinery in tankers for further treatment, pellatisation and sale. A tail gas unit is also provided to ensure 99.8% conversion of the acid gas into sulphur and to meet emission norms. Handling such highly corrosive well fluid throws up a wide range of unique challenges, from upstream, at the well head, to downstream, at the processing facility EPF-50. Kuwait Oil Company (KOC) and Shell signed an Enhanced Technical Service Agreement on February 17 2013 for development of the Jurassic Gas fields. Under the contract, Shell will deploy technical experts to Kuwait to support KOC in its management of the ongoing development of the Jurassic Gas fields. This project is both complicated and challenging, due to unconventional geological formations, difficult reservoir conditions and complex gas compositions.
Operators:
Kuwait Oil Company: Operator with 100% interest
Contractor:
Shell: Enhanced Technical Service Agreement for development of the Jurassic Gas fields
Japan Oil, Gas and Metals Corporation: Testing of enhanced oil recovery
Fluor: EPC primary designs for the project
Schlumberger: Build-operate (BO) contract to install production facilities, including an SRU, at the Sabriya and Umm Niqa fields AND BO contract for the East Raudhatain field
Siirtec Nigi: Design and supply two modular SRUs to the Sabriya and East Raudhatain gas treatment plants
SPETCO: ESTA for 40,000 bpd of oil and 100 mcf (2.8 mcm) per day of gas from West Raudhatain field
Black & Veatch: Two acid gas removal trains and three identical SRUs each with dedicated tail gas treatment units. B&V will also be involved throughout the lifecycle of the project