11-8182-CS-Petrofac-FINAL
- 1. Petrofac Improves Accuracy of Process Designs, Increases Capacity by 20% for Gas Plant Expansion CASESTUDY OILANDGAS
- 2. Petrofac Improves Accuracy of Process Designs, Increases Capacity by 20% for Gas Plant Expansion CASESTUDY OILANDGAS The rigorous Aspen Exchanger Design & Rating models available within Aspen HYSYS速 have enabled us to solve debottlenecking problems in a way not otherwise achievable. - Lakshmi Venkatesh, Petrofac Petrofac is the largest UK-listed service provider to the international oil and gas industry with over 18,000 employees across the globe. Recognized as the top engineering, procurement and construction contractor in the Middle East for the past three years by Oil & Gas Middle East, Petrofac is committed to excellence and strives for increased innovation by continuing to utilize a unique, holistic approach to process modeling. CUSTOMER PROFILE - Petrofac Oil and Gas CHALLENGE Ensure technical and economic feasibility of a gas plant expansion. SOLUTION Aspen HYSYS and Integrated Aspen Exchanger Design & Rating BENEFITS Achieved 20% capacity increase with less than one month payback period Rapidly simulated and evaluated complex alternatives previously difficult to understand with standalone tools Achieved heat exchanger block accuracy for better selection of heat exchangers Improved understanding of process constraints and scale-up Petrofac integrated rigorous heat exchanger models into Aspen HYSYS process flowsheets to debottleneck a gas plant and meet 20% increased capacity requirements.
- 3. Petrofac Improves Accuracy of Process Designs, Increases Capacity by 20% for Gas Plant Expansion CASESTUDY OILANDGAS Petrofac was asked to determine a feasible way to increase the capacity of a gas plant with minimal changes to plant hardware. Using AspenTech products, Petrofac was able to validate the technical and economic feasibility of multiple process improvement schemes. For modeling the process, Aspen HYSYSa process simulator for Oil & Gas applicationswas utilized and Aspen Exchanger Design & Rating (EDR) files were incorporated into the design resulting in a revamp plan with a one month payback period. Petrofac integrated rigorous heat exchanger models into Aspen HYSYS process flowsheets to debottleneck a gas plant and meet 20% increased capacity requirements. RIGOROUS MODELING HELPS DEBOTTLENECK GAS PROCESSES The objective of the study was to revamp a gas plant with minimal changes to the process equipment. The revamp evaluated a 20% increase in production due to the addition of a new oil processing train. In order to accomplish this with minimal CAPEX, the study focused on utilizing existing design margins and relaxing some of the design criteria. This highly economical approach requires the use of accurate process simulation tools to ensure product specifications and plant safety. Aspen HYSYS was used to develop simulation models; however, the heat exchangers used in the flowsheet werent rigorous enough for the study. INTEGRATION OF HEAT EXCHANGER MODELS SAVES CAPITAL COSTS The study revealed that the conventional heat exchanger modeling approaches were inadequatelacking accuracy in correctly predicting thermal and hydraulic performance, which is critical due to the interaction between cold product streams and hot feed streams in the self-refrigerated process. The integration of heat exchanger configurations using Aspen Plate Fin designs (from the Aspen EDR family) in Aspen HYSYS improved the accuracy of the design and resulted in a realistic prediction of the sales gas specifications. Incorporating Aspen EDR within Aspen HYSYS revealed that only two of the three critical heat exchangers required replacement resulting in significant CAPEX savings. VALUE TO PETROFAC The ability to integrate Aspen Plate Fin designs into the simulation flowsheet resulted in an optimal design that minimized CAPEX. This unique capability in Aspen HYSYS increases the accuracy of the simulation results with minimal additional input. Ultimately, the plant revamp costs could be recovered in less than one month of operation. Incorporating Aspen EDR within Aspen HYSYS revealed that only two of the three critical heat exchangers required replacement resulting in significant CAPEX savings.
- 4. CASESTUDY OILANDGAS 息 2015 Aspen Technology, Inc. AspenTech速 , aspenONE速 , the Aspen leaf logo, the aspenONE logo and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-8182-1215 AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE速 solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com. Worldwide Headquarters Aspen Technology, Inc. 20 Crosby Drive | Bedford, MA 01730 | United States phone: +1-781-221-6400 | fax: +1-781-221-6410 | info@aspentech.com Regional Headquarters Houston, TX | United States phone: +1-281-584-1000 S達o Paulo | Brazil phone: +55-11-3443-6261 Reading | United Kingdom phone: +44-(0)-1189-226400 Singapore | Republic of Singapore phone: +65-6395-3900 Manama | Bahrain phone: +973-13606-400 For a complete list of offices, please visit www.aspentech.com/locations