Post on 20-May-2015
2nd Kuwait Lab Technology 2011
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Feb 1 & 2 , 2011, Radisson SAS Hotel, Kuwait
KOC experience: Greener chemicals approach and lab testing
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Background• Kuwait Oil Company
(KOC) - SEK Directorate
• 14 Crude Gathering Centers (GC)
• 2 Effluent Water Disposal Plants (EWDP)
• Total Oil Production = > 1 MM BOPD
• Total Water Disposal = 460,000 BWPD
• Design -500,000BWPD
Greater Burgan
Kuwait Oil Fields
EWDP-1
EWDP-2
2nd Kuwait Lab Technology 2011
2nd Kuwait Lab Technology 2011
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Total Chemical drums per year : 50,950!
1.Demulsifier-I : 22,500 drums
2.Demulsifier-II: 6000 drums
3.Scale inhibitor GC: 4000 drums
4.Corrosion Inh GC: 4,000 drums
5.Scale inh. EWDP: 4000 drums
6.Corrosion Inh EWDP: 4,000 drums
7.Oxygen Scavenger: 2250 drums
8.Rust & Oxidation Inh.: 200 drums
9.Biocide A : 2000 drums
10.Biocide B .: 2000 drums
2nd Kuwait Lab Technology 2011
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1. Shift mode of supply to Bulk containers from drums
2. Mega Storage facility for 3 months stock- KD 14 million
3. Chemicals selection based on Hazard classification
4.Lab Screening/ Field trials for efficiency
5.lab testing –innovative techniques eliminate CFC solvents
6. Data capture Sahala – global award for DM
Greener approach by KOC
2nd Kuwait Lab Technology 2011
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14 SEK
3 NK3 WK
GC
GC
GC/EWDP
EWDP
EWDP
GC
Bulk supply TANKERS-
20 kl
Primary Storage Tank
Demulsifier Type I
Demulsifier Type II
Scale
Corrosion
Demulsifier Type I
D.Tanker
Filling Connection
EF1672
EF1492
EF1492
EF1445
14 SEK3 NK1 WK
EF1672
2. BULK HANDLING FLOW CHART (EF 1672)
Type I4,000
18 Nos Fence
Corrosion
Scale
EF1492EF1672
Day Tanks
Oxygen
Corrosion
Demulsifier Type II
Scale
Type II4,000
2 Nos
GC
Demulsifier Type I
2 WK
EF1445
EF1445 completed
EF1672
14 SEK
3 NK3 WK
14 SEK3 NK
3WK2 EWDP
Secondary Storage Tank
2 EWDP
2 EWDP
EF1672
EF1672
GC
GC
147,000
GC
75,180
42,420
42,420
42,420
205,296 to 55000
( # in usg)
( # in usg)
Corrosion
Oxygen Scavenger
Scale
147,000
205,296 to 55,000
EF1672
50 gpm
50gpm
Adjustment Order for 2 Biocide tanks – 55,000 usg each
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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¨ HSE improvement, cleaner assets¨ KOC image boost as first implementer in GCC/world? ¨ No more empty drums accumulation¨ No more chemical left over in the drums- SAVINGS¨ No more expired chemical drums ¨ No more chemical spillage due to rupture of drums¨ Safe Chemical Handling- no rolling of drums, fumes¨ Better interaction with chemical ¨ no shortage of chemicals- high volume stock available
BULK HANDLING CHEMICAL- ADVANTAGES
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3. Chemicals selection/classification:
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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2nd Kuwait Lab Technology 2011
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4. Chemical screening- example of corrosion inhibitor
Corrosion Inhibitor Selection
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Corrosion Inhibitor Dosage Rates and Residuals
0
10
20
30
40
50
60
70
1-M
ay-0
6
1-J
ul-0
6
1-S
ep-
06
1-N
ov-0
6
1-J
an-
07
1-M
ar-0
7
1-M
ay-0
7
1-J
ul-0
7
1-S
ep-
07
CI (p
pm
)
CI Dosage Rates
CI Residual (Outlet)
Recommended Injection (10-20 ppm)
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Corrosion Rates –sample
Sample # Sequence
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0
3
6
9
12
15
1-M
ay
-06
1-J
ul-
06
1-S
ep
-06
1-N
ov
-06
1-J
an
-07
1-M
ar-
07
1-M
ay
-07
1-J
ul-
07
1-S
ep
-07
OS
(p
pm
) OS Dosage Rates
OS Residual (Outlet)
Recommended Injection (< 15 ppm)
Chemical optimization
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¨ Current methods: Oil in water ¨ EPA US-1664A- HEM (Hexane
Extractable Material)- light ends evaporation.
¨ North sea- OSPAR-Oslo Paris convention new pentane extraction followed by GC-FID
¨ Kuwait – pure analytical grade chloroform/ S-316 solvent
23
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New Equipment
SCF OIW analyzer Gas chromatograph
FLASH POINTH2S ANALYZER
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The TD-500D is a dual channel, handheld fluorometer designed for quick easy &reliable measurement of Crude oil It is ‘NO SOLVENT’ Method Compatible with all popular solvent extraction methods .
¨ The TD-500D responds to the fluorescent aromatic compounds in the target hydrocarbon.¨ The instrument must be calibrated by measuring the intensity of fluorescent light that is generated by a known
concentration of hydrocarbon.¨ Once calibrated, the instrument converts the fluorescent light intensity from unknown sample into units of concentration. The ‘No Solvent Method’ makes possible to perform Oil in water analyses by making fluorescence measurement directly
on the produced water samples . No Organic solvents are required. The method is based upon the addition of a proprietary surfactant to the sample followed by heating, cooling & filtered
into a measurement cuvette. The OIW Sample contains dispersed oil that has been solubilized by OIW Surfactant. A second sample called WSO sample, contains no surfactant . It is simply filtered into a measurement cuvette to remove
dispersed oil, leaving only WSO. Both the OIW &WSO cuvettes are measured by the TD-500D. The dispersed oil concentration is calculated by subtracting the ‘WSO’ measurement from the ‘OIW’ measurement. The
result is reported in ppm.
Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used. Minimum Detection limit is <1 ppm for most oils. Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used. Minimum Detection limit is <1 ppm for most oils.¨ limit is <1 ppm for most oils.
Oil in water fluorescence meter..-solvent free
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Oil in water comparison reportSAMPLE
LOCATION
OIW BY GENESYS -20
(Extraction method) ,ppm
OIW BY TD500D Oil in water meter,
RemarksSample Blank reading
Sample reading after
surfactantResult
IMFH 17.60 -1.00 18.10 19.10 FILTER INLET 13.7 -1.6 23.5 25.10
DISPOSAL OUTLET 11.30 -1.80 19.60 21.40
GC- 8 Effluent water
16.30 -1.50 21.90 23.40
GC- 11 Effluent water
8.4 -0.7 3 3.70
GC- 19 Effluent water
9.1 -1.3 3.7 5.00
BG -551 DISPOSAL 32.20 -1.90 29.60 31.50
BG -551 DISPOSAL 12.30 -1.40 17.10 18.50
INJECTION WELL 132
12.7 -1.5 16.4 17.90
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Well test data
Data suspicio
us?
Gas
Yes
LT-II carries out analysis
Customers accept data
online
Gas LabLT-I
enters data in FINDER
Gas cylinders returned to
GO
LT-I/II enters data in FINDER
Chemist approves
data online
Samples stored for 24 hours then discarded
LT-II carries out analysis
Samples taken
Lab receiving area
-Apply labels-Print log in form-Carry in case
-Sign log in form-Use sample trays
Oil
Yes
Water Water Lab
Sample
type?
Repeat sampli
ng?
Operators access data from FINDER
Data stored in Master
Database
6. Data capture in ShahalaSample & Data Flow Process Diagram
All other data
Yes
No
Oil Lab
LT-I carries out analysis
-Apply SOPs-homogenizer
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Salt (PTB) QC X-CHART
2.12.32.52.72.93.13.33.53.73.94.14.3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample #
Sal
t Con
tent
(PTB
)
UCL
UWL
LWL
LCL
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2nd Kuwait Lab Technology 2011
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THANK YOU
Questions ??