Problems and Prospects of the Helium Industry in Russia

The transition to an innovative way of development in the gas industry is associated with deep, comprehensive processing of natural gas, the start-up of manufacturing products with high added value. In terms of proven reserves of natural gas, Russia ranks number one in the world, the demand is constantly growing both at the domestic market and for exports. Natural and associated petroleum gases of many oil and gas condensate fields in Russia are multicomponent systems that contain a number of components important for the gas chemical industry (ethane, propane, butane, etc.). The most valuable of these is helium. The purpose of this work is to study the problems and prospects for the development of the helium industry in Russia and in the world. Using the methods of economic analysis, generalization and synthesis, the authors estimated the volume of reserves of helium-saturated gases in the fields of the country and Eastern Siberia, the state of helium production, the potential for using helium in the sectors of the Russian economy, the possibility and conditions of competitive entry into the world market. As a result, they detected Russia’s technological inferiority in a number of industries, coming from the low demand for helium, the location of potential consumers far from production centers, the high cost of helium production, the lack of reliable methods of its transportation, etc. At the same time, full-scale helium demand satisfaction of Russian industries is associated with the construction of the Amur Gas Processing Plant. The demand for helium in the countries of the world is constantly growing, an increase in consumption is observed in traditional industries and in the field of innovative technologies. The US dominance in the production of helium is gradually declining due to the depletion of some deposits. The authors make a conclusion that after 2030 Russia can satisfy domestic consumption of helium to bring the industry to an effective economic and environmental level and, while reducing the cost of production, become a major participant in its world market.

Process Modeling, Optimization and Cost Analysis of a Sulfur Recovery Unit by Applying Pinch Analysis on the Claus Process in a Gas Processing Plant

The Claus process is one of the promising technologies for acid gas processing and sulfur recovery. Hydrogen sulfide primarily exists as a byproduct in the gas processing unit. It must be removed from natural gas. The Environmental Protection Agency (EPA) notices that increasing SO2 and CO2 in the air harms the environment. Sulfur generally has an elemental content of 0.1–6 wt % in crude oil, but the value could be higher than 14% for some crude oils and asphalts. It produces SO2 and CO2 gases, which damage the environment and atmosphere of the earth, called primary pollutants. When SO2 gas is reacted with water in the atmosphere, it causes sulphur and nitric acid, called a secondary pollutant. The world countries started desulphurization in 1962 to reduce the amount of sulfur in petroleum products. In this research, the Claus process was modeled in Aspen Plus software (AspenTech, Bedford, MA, USA) and industrial data validated it. The Peng–Robinson method is used for the simulation of hydrocarbon components. The influence of oxygen gas concentration, furnace temperature, the temperature of the first catalytic reactor, and temperature of the second catalytic reactor on the Claus process were studied. The first objective of the research is process modeling and simulation of a chemical process. The second objective is optimizing the process. The optimization tool in the Aspen Plus is used to obtain the best operating parameters. The optimization results show that sulfur recovery increased to 18%. Parametric analysis is studied regarding operating parameters and design parameters for increased production of sulfur. Due to pinch analysis on the Claus process, the operating cost of the heat exchangers is reduced to 40%. The third objective is the cost analysis of the process. Before optimization, it is shown that the production of sulfur recovery increased. In addition, the recovery of sulfur from hydrogen sulfide gas also increased. After optimizing the process, it is shown that the cost of heating and cooling utilities is reduced. In addition, the size of equipment is reduced. The optimization causes 2.5% of the profit on cost analysis.

Assessment of occupational intoxication with aromatic hydrocarbons of the blood of oil and gas industry workers in modern conditions

The oil and gas sector is an essential part of the technical and economic complex of the Russian Federation. The most significant hygienic significance in the oil and gas processing industry is the chemical factor, represented by a complicated complex of harmful substances of hazard class 1-4 with different effects on the body. The study aims to assess the content of benzene and its homologs in the blood of workers of the oil and gas processing industry due to the industrial exposure of chemical factors for five and more than 20 years. Materials and methods. Researchers carried out whole blood samples of 380 oil and gas processing industry workers. They selected two groups for comparison: the main groups of professions (observation group, n=290) and workers not employed in the technological process (comparison group, n=90). During the survey, the scientists have found that with an increase in work experience in the industry up to 10 years, the average group content of toluene, o-xylene, and p,-m-xylene in the blood of workers of the main groups of professions increased from 0.00075 mcg/cm3, 0.00028 mcg/cm3, and 0.00006 mcg/cm3, respectively, to 0.00083 mcg/cm3, 0.00039 mcg/cm3 and 0.00013 mcg/cm3 with more than 20 years of experience in the industry. Those working in the industry in contact with arenas for five and more than 20 years have an increase in the content of cyclic organic compounds in the blood up to 2 times, with an increase in the percentage of blood samples from workers of the primary professions with the content of toluene, o-xylene, and p,-m-xylene up to 83%, 26%, and 13%, respectively. This position confirms the established linear relationships and indicators of the correlation between the content of benzene and o-xylene in the blood of workers of the leading professions and work experience. Workers interacting with risk factors for more than 20 years may get occupational diseases (R2=0.82). With a work experience of more than 20 years, the concentration of aromatic hydrocarbons in workers' blood is 1.5-2 times higher relative to the group of workers not engaged in the technological process. Under experimental studies, we established a correlation between the level of aromatic hydrocarbons (hazard class 1-3 with unidirectional effects on the body) in the blood and work experience in the industry. It is pretty apparent the need to introduce biomonitoring in production to assess the complex intake of substances into the body of workers.

Emissions and Air Quality Implications of Upstream and Midstream Oil and Gas Operations in Mexico

Mexico approved amendments to its constitution in December 2013 that initiated transformational changes to its energy sector. This study developed a 2016 bottom-up emissions inventory for volatile organic compounds (VOCs), nitrogen oxides (NOx), sulfur dioxide (SO2), carbon monoxide (CO), and fine particulate matter (PM2.5) from upstream and midstream sector sources, including onshore and offshore well sites, gas flaring, natural gas processing facilities, and natural gas compressor stations, throughout Mexican basins. Crude oil storage tanks at onshore oil well sites and venting and fugitive sources at offshore oil production sites were the primary sources of VOC emissions. Key contributions to NOx, CO, and PM2.5 emissions were from internal combustion engines at offshore oil well sites and midstream operations. SO2 emissions were associated with onshore and offshore gas flaring and boilers and process heaters at natural gas processing facilities. Application of the inventory with the Comprehensive Air Quality Model with Extensions (CAMx) indicated that oil and gas production operations could contribute to ozone and PM2.5 concentrations in Mexican and U.S. states under favorable transport patterns. This study provides a foundation for assessing the implications of Mexico’s future energy policies on emissions and domestic and cross-border air quality and public health.

Installation Engineering Challenges of the World's Heaviest Topside on Steel Substructure

As part of a green field development project for ADNOC offshore, NPCC here in after called as "contractor", successfully completed installation of an oil and gas processing super complex at offshore Abu Dhabi. This super complex consisted of four large interconnected platforms of different functionalities and an accommodation platform. Associated flare structures and interconnecting bridges were also installed as part of this project. Weights of the topsides in this project were varying from 7,000MT to a ∼32,000 MT. All these topsides were installed by float-over method using contractors own cargo /launch barge fleet. Gas treatment platform topside installed as part of the above project is the world's heaviest single-module topside Installed by float-over on a fixed steel jacket. Float-over is the process of installing the topside on a preinstalled jacket by ballasting and/or by other methods of load transfer such as hydraulic jacks. This installation method is widely used for heavy topsides, due to its cost effectiveness and efficiency. By float over installation method, the topside can be installed as a single integrated unit after completion of all hookup and commissioning works onshore. This paper outlines installation engineering challenges during EPC phase for the gas treatment platform topside. Design of this topside went through phenomenal changes in terms of its size and weight during EPC phase and posed several challenges to install this unit as a single module. This paper presents the installation method, and various parameters considered during installation and also includes discussion on selection of float-over barge, importance of weight control & layout design, finalization of topside support height on barge and installation aids. This paper also presents various installation engineering analyses required during design stage. Float-over installation of the gas treatment platform was carried out by the conventional load transfer method (by ballasting) and using normal spread mooring arrangement.

Procedural Automation of Ethane Recovery to Rejection in NGL Trains

This paper is based on successful implementation of procedural automation of Ethane (C2) recovery - rejection mode change using Yokogawa's Exapilot software, wherein ADNONC Gas Processing Habshan 5 & Sulphur management approved the implementation based on similar success of the Sulphur Recover Unit start-up/shutdown procedural automation & company's drive for digitalisation. Scope was to develop modules for automating C2 Recovery /Rejection change over procedure in NGL unit using M/s Yokogawa Exapilot software. These automated procedures aimed to standardize said mode change over operations by incorporating the operating know how and the expertise of skilled-experienced operators into the Exapilot system as a set of Standard Operating Procedures (SOPs) that are executed in right operating sequence for enhanced operating efficiency. Two main procedures & associated modules were designed, engineered and built using Exapilot to enable single-click change over automation for NGL units. Those were validated with operation and deployed in the Exapilot Server and were integrated with the Operator Consoles (HIS) for access, and was supplemented with operator training. Ethane Recovery to Rejection Mode Change Ethane Rejection to Recovery Mode Change Besides standardization and reduced change over time, this improved the critical asset integrity and lifespan of NGL section equipment by advocating systematic operations. Following benefits including major take away from this project: ➢ Standardized the mode change-over procedures & minimized human error by the digitalization of paper documentation procedures into electronic workflow process. Procedural Automation like Exapilot is powerful tool for digital transformation of batch/discrete operation like unit/equipment start-up/shutdown or grade/mode change over. ➢ Reduced inherent delay due to manual change over. Hence, minimizing the loss-opportunities & operating cost. Besides this tool can be used as training tool (when used in offline mode) which help operator succession plan & effective knowledge transfer ➢ Automated critical operation such as temperature/flow ramping, improved equipment integrity and prolonged equipment life. Procedural Automation using Exapilot thus can improve operation efficiency, asset integrity, equipment or material life span This paper presents a success story of procedural automation of batch operation in continuation of similar success in SRU start-up & shutdown automation. This tool along with proper integration work with DCS, has opened door for automation/digitalization in batch operation in continuous process not only in other sites of ADNOC Gas Processing and other ADNOC Group Companies but also in other industries that helps companies to enhance efficiency and fulfil their digitalization journey. Though Exapilot software belongs to M/s Yokogawa, however other DCS systems have similar software such as Honeywell DCS EPKS has E-procedure for procedural automation.

Control-Oriented Modelling and Optimal Adaptive Control of Parallel Compressors

Compressors are widely used to transport gas offshore and onshore. Oil rigs and gas processing plants have several compressors operating either alone, in parallel or in trains. Hence, compressors must be controlled optimally to insure a high rate of production, and efficient power consumption. The aim of this paper is to provide a control algorithm to optimize the compressors operation in parallel in process industries, to minimize energy consumption in variable operating conditions. A dynamic control-oriented model of the compression system has been developed. The optimization algorithm is tested on an experimental prototype having two compressors connected in parallel. The developed optimization algorithm resulted in a better performance and a reduction of the total energy consumption compared to an equal load sharing scheme.

Upgrade of Plate Heat Exchanger at Optimal Cost Through Core Pack Plate Welding Modification

An innovative design was implemented as a solution for the repetitive failure of a plate heat exchanger installed at Gas Processing Facilitates due to weld cracking, the new design was introduced for the first time in the facility, demonstrating the novelty of utilizing new technologies and enhanced designs in Heat Exchangers used for gas processing. The main challenges were in accommodating various operating modes and ensure the prevention of reoccurrence of the failures. The success was achieved through the collaboration between the operating company and Industry experts in heat transfer equipment to replace the existing design at the gas processing Facilitates with no change in piping layouts, hence, performing the replacement at optimal cost and maximum benefit.

Innovative Reverse Engineering Approach in Design and Construction of New Gas Processing Facility in Brown Field Block Through Optimum Utilization of Excess Materials and Idle Equipment to Improve Capital Stewardship and Inventory Management. Case Study: Field X Associated Gas Recovery Project

Successful project management boils down to effectively and efficiently managing resources to meet the project's cost and schedule. The ability to manage project effectively becomes increasingly important to recover capital project expenditures in expiring Production Sharing Contracts (PSC) blocks. The longer the time needed for a project to complete, the higher the project capital and the lower the capital recovery. Referring to look back result of several major capital facility projects, the key challenge in meeting the project cost and schedule is related to procurement of long lead materials and key process equipment. In brown field blocks, there is an opportunity to perform reverse engineering by optimally utilizing the excess materials in the warehouse and idle/unused process equipment to solve the key challenges. As additional benefit, utilization of excess materials and idle process equipment will improve inventory management and capital stewardship, since the cost to relocate and modify the equipment are significantly lower than the cost of buying a new equipment. Field X Associated Gas Recovery Project (AGRP) provided an excellent case study of successful reverse engineering approach using excess material and idle equipment in design and construction of a new gas processing facility in brown field block. Field X AGRP is designed to recover and process associated gas from X field to be used as fuel gas for the gas turbines at the internal Power Generation Plant. However, based on lesson learned from similar opportunity in the past, the cost of construction and installation of a new gas processing facility using new construction materials and new process equipment is very high, which is uneconomic at the current oil price environment. Therefore, to make the project economic, the project team shall consider the utilization of available excess material in the warehouse and idle/unused equipment into design basis. Project team conducted assessment to several facilities across the concession area to gather equipment specification data of idle process equipment and the size of available excess materials. The gas processing facility design was reverse engineered to optimally utilize the idle process equipment and excess materials. The utilization of idle equipment and excess material in construction of the gas processing facility has successfully generated cost saving up to 5 times the project cost from avoiding purchase of new equipment and new construction materials. The project successfully recovered associated gas at the rate of 0.5 MMSCFD to be used as fuel to gas turbine and produced 60 BOPD condensate from gas-liquid separation process

Resilience Control Room Operator During Pandemic Covid-19

The control room acts as a central nervous system facility. This is where important decisions, using complex systems, are made every day. The actions of control room operators have a direct impact on uptime, production yields, quality, and industrial plant safety. In addition, long working hours per shift result in fatigue, irregularity of circadian rhythms and sleep cycles, and decreased cognitive performance at the end of day and night shifts. Fatigue causes decreased alertness, attention span, poor memory, and concentration and affect other mental factors. ADNOC Gas Processing established Fatigue Risk Management Taskforce (FRMT) to adapt practices to the specific conditions and create a safer working environment, leading to happier and healthier employees and an overall community. In industries that run continuous and heavy-duty plants such as Oil, gas, and petrochemical, shift work ensures production flow. After the outbreak of Covid-19, business needs to adapt quickly so that their activities can run. The finding suggests that the workers' cognitive performance is reduced, shown by the increase of triggered alarm by the average of 14.39% higher than before the outbreak of Covid-19. However, with the ability to adapt and implement control and monitoring measures, the number of alarm rate gradually decreased. The study framework was proven to be a valuable tool that decision-makers can use, especially to measure the performance of control room workers and their psychological fatigue affected by the Covid-19 pandemic.