6.13 Heating System Design Philosophy PDF

KCP-GNS-PCD-DPR-0008
Rev.: 03
Project Title:
Kingsnorth Carbon Capture & Storage Project
Document Title:
Heating System Design Philosophy
Page 1 of 17
Table of Contents
Scope and Functional Requirements ............................................................... 3
1.1 Introduction .................................................................................................... 3
1.2 Design Objectives......................................................................................... 4
1.3 System Description ...................................................................................... 4
1.3.1 Rationale for Heating ............................................................................ 4
1.3.2 Heating Facilities Proposed ................................................................. 5
1.3.3 Heat Transfer Equipment ................................................................... 11
1.4 Quantification of Heating Duties............................................................... 12
1.4.1 Injection Heating Duties ..................................................................... 12
1.4.2 Vent Heating Duties ............................................................................ 13
1.5 Requirement for New Facilities / Further Work ...................................... 13
2. Assumptions....................................................................................................... 14
3. Design Requirements ....................................................................................... 15
3.1 Heat Loads .................................................................................................. 15
3.2 Temperature ................................................................................................ 15
3.3 Pressure ....................................................................................................... 15
3.4 Physical Properties..................................................................................... 16
3.5 Materials of Construction........................................................................... 16
3.6 Insulation ...................................................................................................... 16
3.7 Equipment Isolation / Protection .............................................................. 16
3.8 Process Control .......................................................................................... 16
4. Mandatory References ..................................................................................... 17
5. Supporting References..................................................................................... 17
1.
Kingsnorth CCS Demonstration Project

The information contained in this document (the Information) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, employees, advisers, and the Department of Energy and Climate Change (DECC) make no
representation or warranty as to the accuracy, reliability or completeness of the Information and neither E.ON UK plc nor any of its subcontractors,
subsidiaries, affiliates, employees, advisers or DECC shall have any liability whatsoever for any direct or indirect loss howsoever arising from the use of the
Information by any party.
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Page 2 of 17
Table of Figures
Figure 1-1 Gaseous Phase Case - Offshore Process Infrastructure ................ 6
Figure 1-2 : Proposed Offshore Infrastructure with Fired Heater ..................... 8
Figure 1-3 Full Flow Case With Separate Heaters on Each Flowline............. 10
Figure 1-4 : Estimated Field Life Injection Duties for Steady State Dense
Phase Operation and 1600 MWg Power Plant Capacity .......................... 12

Rev.: 03
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Document Title:
1.
Scope and Functional Requirements
1.1
Introduction
Page 3 of 17
This design philosophy describes the design requirements for the

Heating System that is to be located offshore. The design
philosophy will ensure that a consistent approach is taken by all
parties throughout the design, construction and operational phases
of the project.
This document will cover the following elements:
Design Criteria
Rationale for Heating
Heating System Users
Quantification of Heating Duties
Consideration of Heating Source
Requirement for New Facilities / Further Work
Heating will be required at the offshore infrastructure to avoid
compromising system design temperatures. However, equipment
that is downstream of the heater must be designed to cope with
short term low temperatures in the event of heater failure.
Additionally, heating is also required to protect the reservoir and
wells from being subjected to multi-phase flow and low
temperatures created by very cold CO2 that will be generated when
there is a large differential pressure across the topsides choke
valve. Such a scenario will persist mainly during dense phase
operation of the system (start-up and normal operation), especially
at lower reservoir pressures. However, there is also the potential
for it to occur during line packing and / or start-up of the system
when operating in gas phase mode.
Therefore heating at the offshore infrastructure will be required for
both modes of operation (S1 & S2).

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1.2
Page 4 of 17
Design Objectives
The design objective is to ensure that essential heating
requirements are supplied to the facilities under all foreseeable
operating circumstances in the most effective manner. The system
should also be able to be controlled / monitored remotely including
start-up and shutdown.
Priority shall be given to health, safety and environmental issues
with a view to identification and elimination of potential hazards
before they become a problem.
1.3
System Description
1.3.1
Rationale for Heating

It is anticipated that heating for the injection of CO 2 at the offshore
infrastructure will be required for dense phase mode start-up and
normal operation, for gas phase mode start-up and line packing,
and potentially depressurisation / venting activities.
Heating will only be required during situations when significant
pressure drops are taken across the topsides choke valve e.g. for
normal dense phase operation. Heating will be required to avoid
compromising system design temperatures but also protect the
reservoir from being damaged by very cold CO2. It is not
anticipated that heating will normally be required for gaseous
phase operation when the pressure drop across the topsides choke
should be small or minimal.
Heating may also be required for depressurisation/venting activities
to aid CO2 dispersion, to prevent solids formation in the vent
system and avoid a visible plume of CO2 snow being discharged.
However, the requirement to provide vent heating needs to be
reviewed further; it is only an assumption that it is required at this
stage. Refer to the Pressure Let-down System Design
Philosophy, Doc. No. KCP-GNS-PCD-DPR-0004 for further details
on venting requirements S3.

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1.3.2 Heating Facilities Proposed

1.3.2.1
Gaseous Phase Demonstration Phase
It is anticipated that heating will only be required during the gaseous

phase of operation for system/wells start-ups or for allowing reduced
flow of CO2 into individual wells.
The peak total heating duty, which needs to be confirmed, is
anticipated to be approximately 2 MW.
The only feasible approach to adding heat to the CO 2 in this mode of
operation would be by separate electrical heaters on each well. This
is due to the following reasons:Due to the complicated nature and unreliability of fired heaters,
then the use of a fired heater on the offshore facility would
require personnel to be permanently based offshore. An
electrical heater is simpler, much easier to start remotely and is
much better suited to a normally unmanned facility.
Multiple heaters would be required to ensure that adequate
system availability is maintained. In addition, individual wells
may require separate heating due to varying conditions in that
particular injection string. A separate heater on each well would
meet all of the availability and flexibility requirements for the
system.
A fired heater would require additional hydrocarbons to either be
stored on the facility (diesel), or piped in (fuel gas). The offshore
safety risks for this these alternatives are much greater than for
an electrically heated option.
A separate heater may also be required on the vent system.
However, use of the process heaters for this duty maybe feasible
and will need to be investigated.
Figure 1-1 provides the proposed flowscheme for the electrically
heated gaseous phase mode of operation. It should be noted that
the flowschemes in this philosophy are intended to be used to show
the configuration, number and type of the heaters only, and that
some features, such as the position of the meters, may change.
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Page 6 of 17
Figure 1-1 Gaseous Phase Case - Offshore Process Infrastructure

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1.3.2.2
Page 7 of 17
Dense Phase Full Flow Case

In order to accommodate the heating scenarios identified in the
previous sections, the following heating equipment and
configuration may be required for the dense phase mode of
operation (See Figures 1-2 and 1-3 below). It should be noted that
the final topsides configuration and means of supplying heat to the
CO2 needs to be confirmed. The options utilizing seawater as the
heating medium were evaluated in two separate decision papers S4
and S5
, which were completed in a previous phase of the project.
These decision papers recommended that the seawater heating
options are to be discounted from further evaluation. Two design
options that are to be considered further are presented below.
1. Single Fired (Direct or Indirect) or Single Electric Heater
Scheme (Fig 1-2)
A fired heater or electric heater will be utilised upstream of the
topsides choke valve to raise the injection temperature to the
required value.
The fired heating system maybe direct fired or indirect. The indirect
system would use a fired heater to warm up a separate closed loop
heating medium system.
A fired / electric heater is also allowed for on the vent line.

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Page 8 of 17
Figure 1-2 : Proposed Offshore Infrastructure with Fired Heater1
Proposed Infrastructure taken from ITT submission D172 and shows a fired heater and
depressurisation heater and a riser base ESDV. The actual system layout maybe different
from this when the final offshore flowscheme is developed.
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Page 9 of 17
1. Electrical Heating on Each Individual Well (Fig 1-3)

This system is effectively an expansion upon the scheme that is
proposed to be used for the gaseous phase of operation. This
option utilizes an electrical heater on each well flowline upstream of
each choke valve.
An electric heater is also allowed for on the vent line.

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Page 10 of 17
Figure 1-3 Full Flow Case With Separate Heaters on Each Flowline

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Page 11 of 17
1.3.3 Heat Transfer Equipment

The final heating scheme and majority of components within the
heating system and their type are still to be confirmed. The
following components should be considered when selecting the
final design:
1. Fired Heater A directly fired heat exchanger may be able to be
installed. However there could be concerns regarding corrosion
on the external bundle walls caused by the cold CO 2 being
carried in the tubes.
If a directly fired heat exchanger becomes unattractive then a
system incorporating an intermediate heating medium system
could be installed. This system could include circulation pumps,
expansion and storage tanks, filters, associated piping, valves
and instrumentation. An appropriate heating medium would
need to be selected.
2. Electric Heater An electric heater could be an alternative to a
directly fired heater. Using this system would also remove a lot
of HSE issues associated with having a hydrocarbon fired
heater installed on the platform. It should be noted that
significantly sized thyristor panels would also need to be
provided for with this option (i.e. a larger electrical scope
associated with this option).
Another significant attraction about this type of heater is its
ability to be used on an Normally Unmanned Installation, due to
its inherent simplicity and reliability.

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1.4
Page 12 of 17
Quantification of Heating Duties

1.4.1
Injection Heating Duties

The amount of heating required will depend on the flow scheme
option selected, reservoir pressure and CO2 flowrate. Figure 1-4
details the estimated steady state heating duties required for the
full power plant capacity of 1600 MWg2.
The figure shows the fired / electric heater duty required to ensure
single phase flow down the injection wellbore. It also details the
seawater heater duty to ensure fluids entering the well bore are at
0C. The heating duties assume normal operation of the system in
dense phase mode, gas phase heating will not require be required
except for start-up. The use of seawater as the heating medium
has since been discounted from further consideration, but this
data is purely provided for information only.
Figure 1-4 : Estimated Field Life Injection Duties for Steady State Dense
Phase Operation and the full 1600 MWg Power Plant Capacity
Steady State Injection Heating at Offshore for a Power Plant Capacity of 1600 MWg
(Dense Phase Operating Cases)
20
18
16
14
Duty (MW)
12
10
8
6
4
2
0
0
20
40
60
80
100
120
140
160
Reservoir Pressure (bar)

Fired Heater
Sea Water Heater
For alternative power plant capacities the heating duty can be pro-rated to
estimate the required heating duty.
180
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1.4.2 Vent Heating Duties

The requirement to install a vent heater will need to be decided
when dispersion studies have been investigated. If it is required the
heating duties will need to be determined based upon the worst
case depressurisation rates and the amount of heating to ensure
the required dispersion is achieved.
1.5
Requirement for New Facilities / Further Work

The need for further modeling to establish the behavior of high
pressure CO2 depressurisation to atmosphere needs to be
performed to determine if a vent line heat exchanger is required or
not.
The preferred flow scheme and means of supplying heat offshore
needs to be determined (i.e. fired direct, fired with heating medium,
electric etc).
Whether capacity upgrades in the future are likely. This will need to
be known so that sufficient platform space is allowed for in the
design for future expansion of the heating system (e.g. Thames
Cluster).

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2.
Page 14 of 17
Assumptions
1. The offshore facility will be a Normally Unmanned Installation
(NUI), if at all possible.
2. The heating system will initially be designed to handle the CO2
flow for the demonstration case (6600 tonnes/day), which is of
the full CO2 flow from the 1600 MWg power plant. Heating duties
are presented in this philosophy for the full power plant capacity
(1600 MWg). The heating duties for lower power plant outputs,
during dense phase operation, should use the data from the
1600 MWg case and prorate them accordingly.
3. It is assumed for the full flow scheme that the preferred heating
arrangement and means of providing heating energy offshore
will be determined in the next stage of design.
4. A vent heater has been assumed to aid CO2 dispersion and
avoid a visible plume of CO2 snow. The requirement for this
equipment item needs to be checked through dispersion studies
etc.
5. In order to avoid the requirement for high integrity low
temperature trip systems, then systems that are downstream of
the heater will be designed to cope with short term exposure to
very low temperatures (minus 78 deg C). This event could occur
in the event of heater failure.
6. The use of a local reservoir as the fuel gas source has been
discounted for the fired heater option. This is due to the fact that
the additional fuel gas treatment facilities would be required, and
the fact that it is extremely unlikely that the source of fuel gas
would be available for the 40 year design life.

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3.
Design Requirements
3.1
Heat Loads
Page 15 of 17
The heating loads detailed in Figure 1-4 should be taken as

indicative values for dense phase operation of the injection system
taking all the CO2 from a 1600 MWg power plant.
Any start-up duties / partial fired heater duties will need to be
confirmed at the next stage of design when the flow scheme and
means of providing heat have been selected.
Sufficient platform space should be allowed for future expansion of
the injection system.
3.2
Temperature
The design temperatures of the heating system are to be confirmed
at a later stage of design, once the flow scheme and means of
providing heat has been agreed. However, it should be noted that
items subjected to CO2 downstream of a choke valve could see
temperatures as low as -78C (assuming no upstream heating).
To guarantee a single phase fluid downstream of the choke valve
(during dense phase operations), the CO2 fluids need be heated to
ensure the temperature downstream of the choke is above the
critical temperature of CO2, which is circa 32C.
The heater outlet temperature will be dictated by the pressure
upstream and downstream of the choke.
It should be noted that heating during the gaseous phase operation
should not normally be required.
3.3
Pressure
The design pressures of the heating system are to be confirmed at
a later stage of design, once the flow scheme and means of
providing heat has been agreed. The maximum pressure will partly
be determined by the need for line packing of the flowline (to act as
CO2 storage) and could exceed 200 barg.

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3.4
Page 16 of 17
Physical Properties
The physical properties of the heating medium will be advised at a
later stage of design, if this option is selected at the next stage of
design.
3.5
Materials of Construction
Reference should be made to the Materials Selection Report For
Offshore Infrastructure Phase 1A, Doc. No. KCP-GNS-PLD-REP0009. Appropriate materials of construction should be selected.
These will depend on what flow scheme and the means of heating
selected. It should be noted that care must be taken when selecting
elastomers in contact with CO2, due to the potential for the
adsorption of high pressure CO2 into components. It is therefore
recommended that extensive testing takes place of any selected
elastomers that could come into contact with pressurized CO2.
3.6
Insulation
Depending on the heating option selected at the next stage of
design personnel protection and or heat conservation insulation
may be required on the heating system.
3.7
Equipment Isolation / Protection

Suitable equipment isolation and over pressure protection etc will
need to be provided for depending on the heating solution selected.
3.8
Process Control
The heating system on the offshore installation shall be designed to
be self regulating. The control philosophy will be to provide
sufficient heat to the CO2 such that it can be injected / vented at the
correct temperature.
Given that the offshore installation will be largely unmanned, the
system should have the ability to be started / stopped remotely.
This will be considerably easier in the case of the electric heater.
The performance of the system will require to be monitored by
onshore operators.

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Page 17 of 17
4.
Mandatory References
M1
ASME Boiler and Pressure Vessel Code: Rules for Construction of

Pressure Vessels ASME VIII.
To be developed further when heating solution selected.

5.
Supporting References
S1
Internal Report.
S2
Intrernal Report.
S3
Pressure Let-down System Design Philosophy

Doc. No. KCP-GNS-PCD-DPR-0004 Rev 01.
S4
Internal Report.
S5
Internal Report.
S6
Power Supply Design Philosophy, Doc. No.

KCP-GNS-PSP-DPR-0001 Rev 01.


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KCP-GNS-PCD-DPR-0008

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Heating System Design Philosophy

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Scope and Functional Requirements

This design philosophy describes the design requirements for the

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Rationale for Heating

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

1.3.2 Heating Facilities Proposed

Gaseous Phase Demonstration Phase

It is anticipated that heating will only be required during the gaseous

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Figure 1-1 Gaseous Phase Case - Offshore Process Infrastructure

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Dense Phase Full Flow Case

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Figure 1-2 : Proposed Offshore Infrastructure with Fired Heater1

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

1. Electrical Heating on Each Individual Well (Fig 1-3)

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

1.3.3 Heat Transfer Equipment

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Quantification of Heating Duties

Injection Heating Duties

Reservoir Pressure (bar)

Sea Water Heater

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

1.4.2 Vent Heating Duties

Requirement for New Facilities / Further Work

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project

Heating System Design Philosophy

The heating loads detailed in Figure 1-4 should be taken as

Kingsnorth CCS Demonstration Project

Kingsnorth Carbon Capture & Storage Project