Kuppusamy Uthman - koc kuwait

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Kuppusamy Uthman - koc kuwait

  1. 1. Feb 1 & 2 , 2011, Radisson SAS Hotel, Kuwait<br />KOC experience: Greener chemicals approach and lab testing<br />www.kockw.com<br />
  2. 2. 2nd Kuwait Lab Technology 2011 <br />Background<br />Kuwait Oil Fields <br /><ul><li>Kuwait Oil Company (KOC) - SEK Directorate
  3. 3. 14 Crude Gathering Centers (GC)
  4. 4. 2 Effluent Water Disposal Plants (EWDP)
  5. 5. Total Oil Production = > 1 MM BOPD
  6. 6. Total Water Disposal = 460,000 BWPD
  7. 7. Design -500,000BWPD</li></ul> Greater Burgan<br />EWDP-1<br />EWDP-2<br />
  8. 8. Total Chemical drums per year : 50,950! <br />Demulsifier-I : 22,500 drums <br />Demulsifier-II: 6000 drums <br />Scale inhibitor GC: 4000 drums<br />Corrosion Inh GC: 4,000 drums<br />Scale inh. EWDP: 4000 drums<br />Corrosion Inh EWDP: 4,000 drums<br />Oxygen Scavenger: 2250 drums<br />Rust & Oxidation Inh.: 200 drums <br />Biocide A : 2000 drums<br />Biocide B .: 2000 drums <br />
  9. 9. Greener approach by KOC<br />Shift mode of supply to Bulk containers from drums<br /> Mega Storage facility for 3 months stock- KD 14 million<br /> Chemicals selection based on Hazard classification<br />Lab Screening/ Field trials for efficiency <br />lab testing –innovative techniques eliminate CFC solvents<br />Data capture Sahala – global award for DM<br />
  10. 10. 2. BULK HANDLING FLOW CHART(EF 1672)<br />Primary Storage Tank <br />Secondary Storage Tank<br />( # in usg)<br />Day Tanks<br />Filling Connection<br />( # in usg)<br />14 SEK<br />3 NK<br />1 WK<br />Type I<br />4,000<br />18 Nos<br />Fence<br />GC <br />GC <br />EF1672<br />EF1672<br />147,000<br />Demulsifier Type I<br />50 gpm<br />Demulsifier<br /> Type I<br />2 WK<br />EF1672<br />Type II<br />4,000<br />2 Nos<br />GC <br />GC <br />Demulsifier<br /> Type II<br />EF1672<br />50gpm<br />Demulsifier Type I<br />147,000<br />14 SEK<br />EF1445<br />GC<br />3 NK<br />3 WK<br />EF1672<br />75,180<br />Demulsifier Type II<br />Scale<br />14 SEK<br />EF1445 completed<br />Corrosion<br />GC<br />3 NK<br />3 WK<br />42,420<br />Scale<br />EF1672<br />D.Tanker<br />GC<br />Bulk supply TANKERS- 20 kl<br />Oxygen<br />Corrosion<br />EF1445<br />42,420<br />14 SEK<br />3 NK<br /> 3WK<br />EF1672<br />EF1492<br />2 EWDP<br />GC/EWDP<br />42,420<br />EF1492<br />Oxygen Scavenger<br />2 EWDP<br />Scale <br />EWDP<br />Scale<br />EF1492<br />205,296 to 55000<br />Corrosion <br />2 EWDP<br />Corrosion<br />EWDP<br />Adjustment Order for 2 Biocide tanks – 55,000 usg each<br />205,296 to 55,000 <br />
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  14. 14. BULK HANDLING CHEMICAL- ADVANTAGES<br />HSE improvement, cleaner assets<br />KOC image boost as first implementer in GCC/world? <br /> No more empty drums accumulation<br />No more chemical left over in the drums- SAVINGS<br />No more expired chemical drums <br />No more chemical spillage due to rupture of drums<br />Safe Chemical Handling- no rolling of drums, fumes<br /> Better interaction with chemical <br /> no shortage of chemicals- high volume stock available<br />
  15. 15. 3. Chemicals selection/classification:<br />
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  24. 24. 4. Chemical screening- example of corrosion inhibitor<br />Corrosion Inhibitor Selection<br />
  25. 25. Corrosion Inhibitor Dosage Rates and Residuals<br />
  26. 26. Corrosion Rates –sample <br />Sample # Sequence<br />
  27. 27. 22<br />Chemical optimization<br />
  28. 28. Current methods: Oil in water <br /> EPA US-1664A- HEM (Hexane Extractable Material)- light ends evaporation.<br />North sea- OSPAR-Oslo Paris convention new pentane extraction followed by GC-FID  <br />Kuwait – pure analytical grade chloroform/ S-316 solvent<br />23<br />
  29. 29. New Equipment<br />SCF OIW analyzer<br />Gas chromatograph<br />FLASH POINT<br />H2S ANALYZER<br />
  30. 30. The TD-500D is a dual channel, handheld fluorometer designed for quick easy &reliable measurement of Crude oil <br />It is ‘NO SOLVENT’ Method Compatible with all popular solvent extraction methods . <br />The TD-500D responds to the fluorescent aromatic compounds in the target hydrocarbon.<br />The instrument must be calibrated by measuring the intensity of fluorescent light that is generated by a known concentration of hydrocarbon.<br />Once calibrated, the instrument converts the fluorescent light intensity from unknown sample into units of concentration.<br /><ul><li>The ‘No Solvent Method’ makes possible to perform Oil in water analyses by making fluorescence measurement directly on the produced water samples .
  31. 31. No Organic solvents are required.
  32. 32. 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.
  33. 33. A second sample called WSO sample, contains no surfactant . It is simply filtered into a measurement cuvette to remove dispersed oil, leaving only WSO.
  34. 34. Both the OIW &WSO cuvettes are measured by the TD-500D.
  35. 35. The dispersed oil concentration is calculated by subtracting the ‘WSO’ measurement from the ‘OIW’ measurement. The result is reported in ppm.
  36. 36. Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used.
  37. 37. Minimum Detection limit is <1 ppm for most oils.
  38. 38. Usage of Organic solvents like Chloroform, Hexane , xylene was avoided instead a OIW Surfactant was used.
  39. 39. Minimum Detection limit is <1 ppm for most oils.</li></ul>limit is <1 ppm for most oils.<br />Oil in water fluorescence meter..-solvent free<br />
  40. 40. Oil in water comparison report<br />
  41. 41. 6. Data capture in Shahala<br />Sample & Data Flow Process Diagram<br />Repeat sampling?<br />Yes<br />Samples taken <br />-Apply labels<br />-Print log in form<br />-Carry in case<br />Operators access data from FINDER<br />Yes<br />LT-II carries out analysis<br />Data suspicious?<br />Oil Lab<br />LT-I/II enters data in FINDER<br />Lab receiving area<br />Oil<br />-Sign log in form<br />-Use sample trays<br />Sample type?<br />LT-II carries out analysis<br />Water Lab<br />Water<br />No<br />Chemist approves data online<br />Customers accept data online<br />Well test data<br /> Gas<br />LT-I enters data in FINDER<br /> Yes<br />LT-I carries out analysis<br />Gas Lab<br />All other data<br />Data stored in Master Database<br />Samples stored for 24 hours then discarded<br />Gas cylinders returned to GO<br />-Apply SOPs<br />-homogenizer<br />
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  44. 44. THANK YOU<br />Questions ??<br />

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