PCB 1052

INTRODUCTION to OIL & GAS

SURFACE FACILITIES

PETRONAS Management Training Sdn Bhd 2006.

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SURFACE FACILITIES SUBSEA DEVP CONCEPT

INTRODUCTION

The basic equipment common to many surface

processing facilities include:
Wellhead and manifold
Separators
Oil treaters
Water treaters
Pumps
Compressors
Gas dehydrator
Condensate stabilization
Acid gas treater
Well testing equipment
Lease automatic custody transfer (LACT)

SURFACE FACILITIES SUBSEA DEVP CONCEPT

INTRODUCTION SUBSEA HARDWARE

The fluids
produced from
wells are usually
directed through
flow lines and
manifolds
(gathering
system) to a
central location
for processing
and treatment.

SURFACE FACILITIES SUBSEA DEVP CONCEPT

Well Head

The gathering
wellhead

system

begins

at

the

The wellhead should include at least one

choke used to control the well production
If the upstream pressure is too high it is
recommended to use a positive choke in
series with an adjustable choke. In case the
adjustable choke fails, the positive choke
keep the production limited
An automatic shut-down valve can quickly
interrupt production in case of an event
Block valves are also required to perform
regular maintenance on the choke

SURFACE FACILITIES SUBSEA DEVP CONCEPT

SUBSEA HARDWARE Xmas TREE

SURFACE FACILITIES SUBSEA DEVP CONCEPT

SUBSEA HARDWARE WET TREE
Cluster

SURFACE FACILITIES SUBSEA DEVP CONCEPT

SUBSEA HARDWARE MANIFOLD
When the production of two or more wells is commingled in a central
facility it is necessary to install a manifold to allow the production of the
wells into the common production line or the well test line

Christmas Tree Components - 1

Christmas Tree Components - 2

SURFACE FACILITIES

SURFACE FACILITIES PROCESS DESIGN

Flow Diagram

Process Flow
Schemes of flow
charts are commonly

used to present
details of the
process. It is very
important to
understand the

symbol convention
used in those charts

SURFACE FACILITIES
PROCESS DESIGN

Design of Equipment depends on Physical Properties,

Phase Behavior and Flow of Hydrocarbon Fluids.
Physical Properties affecting equipment design
are: vapor pressure, density, molecular weight,
viscosity, surface tension, composition and
gas/liquid volumes.
Phase Behavior is the change in relationship
between phases at various conditions.
Fluid Flow properties affecting transmission
system design are: viscosity and type of flow.

SURFACE FACILITIES PROCESS DESIGN

PHYSICAL PROPERTIES

Physical properties
Density
Viscosity
Formation volume factor
Compressibility
Thermal expansion
Surface tension

Need to predict pressure-volume-temperature (PVT)

behavior of gas to estimate its properties
Techniques used to predict PVT behavior are
Equation of State (EOS)
Corresponding States Principle
Empirical Correlations

SURFACE FACILITIES PROCESS DESIGN

Fluid Flow

Transport properties of oil and gas are significant in the design of

equipment and flowlines

Viscosity - indicates fluids resistance to flow

Reynold's number - used to identify flow regime

Laminar Flow exist at Re < 2000

Turbulent Flow exist at Re > 4000

SURFACE FACILITIES

SURFACE FACILITIES OIL PROCESSING

BASIC SEPARATION

SURFACE FACILITIES OIL PROCESSING

SEPARATION SYSTEM

Separation is required - gas and liquid require

different processing methods.
Separators are classified by physical shape,
function or number of phases they separate.
Separator separate a combined liquid-gas flow
Two-phase gas and liquid separation
Three-phase gas, liquid and water separation
Scrubber handle stream with unusually high
gas-to-liquid ratios
Produced Water Handling separate free water
Filter remove solids from gas/liquid stream.

SURFACE FACILITIES OIL PROCESSING

SEPARATOR

Gas

Liquid

Two Phase

Three Phase

SURFACE FACILITIES OIL PROCESSING

VERTICAL SEPARATOR

Advantages
Liquid level and fluids control
not critical
Easier and cheaper to design
for surge capacity
Can handle solids with certain
design
Easier to clean
Disadvantages
More expensive
Does not adapt to skidmounted assemblies well
Requires larger diameter for
same gas capacity.

SURFACE FACILITIES OIL PROCESSING

HORIZONTAL SEPARATOR

Advantages
Less expensive
More adaptable to skidmounting
More available area for settling
More adaptable to
accommodate heating coils or
sand jets
Can more effectively handle
foamy crude

Disadvantages
Has less liquid surge
capacity
Liquid level control
is more critical

SURFACE FACILITIES OIL PROCESSING

MULTISTAGE SEPARATION

Oil and gas separation carried on in several stages

at successively lower pressures.
The more stages of separation the fluids go
through the more perfect the overall separation will
be.
Separation efficiency increases resulting in higher
percentage of recoverable liquids.

SURFACE FACILITIES OIL PROCESSING

MULTISTAGE SEPARATION

SURFACE FACILITIES OIL PROCESSING

GAS SEPARATION SYSTEM

Gas and condensate flow from wellheads to the 3

phase production separator which separate water
from the condensate and gas
Gas is then sent to the glycol dehydration system,
condensate to condensate Flash Tank and
produced water to skimmer
Produced gas is dried by contacting it with
Triethylene Glycol (TEG) liquid
Condensate from Flask Tank is passed to
Coalescer which allow nearly total removal of
remaining produced water

Oil Processing

SURFACE FACILITIES

SURFACE FACILITIES WATER TREATMENT

Two primary needs for water processing:

Disposal
Treatment of produced water separated from
oil and gas prior to disposal in an
environmentally acceptable manner .
Injection
Cleaning of source water from rivers or sea
before wellbore injection in EOR projects to
minimise zone plugging and maintain high
injection rates.

SURFACE FACILITIES WATER TREATMENT

The contents of an oil reservoir may be considered

as consisting of three major components gas,
crude oil and water. Of these three, gas and oil are
saleable products, whereas water unless used for
injection purposes, is a WASTE PRODUCT.
The water, separated out from the oil and gas in
the platform separation trains, is known as
PRODUCED WATER.
Before Produced Water can be either disposed off
into the sea or used for injection purposes it
requires treatment.

SURFACE FACILITIES WATER TREATMENT

SURFACE FACILITIES WATER TREATMENT

Water collected from processing facilities

contains:
Suspended oil droplets
Dissolved gases
Entrained solids

Selected treatment and disposal method

determines:
Water quality target at minimum cost and
Satisfies applicable rules, regulations or laws.

SURFACE FACILITIES

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

GAS or WATER INJECTION SYSTEM

The completeness of recovery by water-flooding or

gas injection, depends largely on two factors of
efficiency:
Displacement efficiency
Sweep efficiency.
Displacement efficiency is the proportion by
volume of the oil swept out of reservoir's pores by
the displacing fluid. Displacement occurs at the
microscopic level.
Sweep efficiency refers to the portion of total
reservoir volume that can be contacted or swept
by the displacing fluid (Macroscopic level).

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

GAS or WATER INJECTION SYSTEM

Reason
WHAT

Description

Secondary recovery
Source Sea water/produced water
& produced gas.
Improve production potential from
reservoir

WHERE

Injected into reservoir

WHY

Replace fluid oil, water & gas

Maintaining reservoir pressure
Enabling producing of oil

WHEN

Production of oil decrease

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

GAS or WATER INJECTION SYSTEM

Liquid
Bbl/Day

PRIMARY RECOVERY

GAS or WATER INJECTION

Time (Year)

Water Disposal

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

ARTIFICIAL LIFT SYSTEM

Completed producing wells will usually produced fluids from Wellbore

to the surface by means of Natural Reservoir Energy.

Artificial lift is supplemented into well tubing pressure during their

Economic Life in order to obtain maximum recovery of oil for
maximum profit before its Economic Limit of producing life is

reached.

Notable exceptions are wells completed in a prolific water drive

reservoir where wells may continue to flow until as much as 100 %
saltwater production is obtained. The usual experience is that a well

will require some means of artificial lift

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

ARTIFICIAL LIFT SYSTEM

Hydraulic Lift

SURFACE FACILITIES - PRODUCTION SUPPORT FACILITIES

ARTIFICIAL LIFT SYSTEM
Reciprocating
Rod Lift

Progressive
Cavity Pump

Gas Lift

Plunger Lift

Hydraulic Lift

Hydraulic Jet

Electric
Submersible
Pump

Operating
Depth

To 16,000
TVD

To 16,000
TVD

To 15,000
TVD

To 19,000
TVD

To 17,000
TVD

To 15,000
TVD

To 15,000
TVD

Operating
Volume

To 6,000
BFPD

To 4,500
BFPD

To 30,000
BFPD

To 200
BFPD

To 8,000
BFPD

To 15,000
BFPD

To 40,000
BFPD

Operating
Temperature

To 550oF

To 235oF

NA

To 550oF

To 550oF

To 550oF

To 400oF

Corrosion
Handling

Good to
Excellent

Fair

Good to
Excellent

Excellent

Good

Excellent

Good

Gas
Handling

Fair to Good

Good

Excellent

Excellent

Good

Fair

Good

Solids
Handling

Fair to Good

Excellent

Good

Fair

Fair

Good

Fair

Fluid
Gravity

> 80 API

> 350 API

> 150 API

> 150 API

> 80 API

> 80 API

> 100 API

Servicing

Workover or
Pulling Rig

Workover or
Pulling Rig

Wireline or
Workover

Wellhead
Catcher or
Wireline

Hydraulic or
Wireline

Hydraulic or
Wireline

Workover or
Pulling Rig

Prime
Mover

Gas or
Electric

Gas or
Electric

Compressor

Wells Nature
Energy

Multicylinder
or Electric

Multicylinder
or Electric

Electric Motor

Offshore
Application

Limited

Good

Excellent

NA

Good

Excellent

Excellent

Efficiency

45% to 60%

40% to 70%

10% to 30%

NA

45% to 55%

10% to 30%

35% to 60%

SURFACE FACILITIES

SURFACE FACILITIES
CRUDE & GAS STORAGE

Major goals in providing clean product storage:

To furnish sufficient storage volume to
minimize production operations down-time.
To prevent volumetric loss or quality
degradation while product is in storage
To avoid pollution.

Factors governing selection of storage mode are:

Economic considerations
Safety considerations
Pollution Control.

SURFACE FACILITIES
CRUDE & GAS STORAGE

Economic considerations:
Unit cost of storage and associated facilities
Operating and maintenance costs
Capability of future expansion
Cost of land
Oil conservation and vapor prevention.

SURFACE FACILITIES
CRUDE & GAS STORAGE

Safety considerations:
Proximity to property line
Spacing requirements
Prevention of hydrocarbon release to the
atmosphere
Vapor pressure and other physical properties
of the product to ensure safe storage
Dike (or Dyke) requirements
Pressure vacuum relief valves.

SURFACE FACILITIES CRUDE & GAS STORAGE

TANK TYPES STORAGE

SURFACE FACILITIES CRUDE & GAS STORAGE

NON-CONVENTIONAL STORAGE

SURFACE FACILITIES

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT

Transfer mechanical energy to a process fluid or

convert the fuel energy (chemical energy) to shaft
work.

Two basic categories:

Driven Equipment pumps, compressors, generator
Prime Movers reciprocating engines, gas turbine,
electric motor, steam turbine

A rotating equipment installation consists of

driven equipment connected to a prime mover
through a coupling or a gear box.

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT

Pumps

A equipment device that applies mechanical

energy to fluid.

Compressors

Used for compressing natural gas from separators

for fuel and sales, gas pipeline transmission, gas
lift and re-injection, and in process refrigeration
systems.

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT PUMP
Pump

Positive
Displacement

Reciprocating

Piston
Plunger
Diaphragm

Rotary

Vane
Gear
Lobe
Screw

Kinetic

Peripheral

Centrifugal

Radial Flow
Axial Flow
Mixed Flow

Special
Type

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT COMPRESSOR
Compressor

Positive
Displacement

Reciprocating

Piston
Diaphragm

Rotary

Vane Lobe
Screw

Dynamic

Jet
Aspirator

Rotary

Centrifugal
Radial
Axial

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT COMPRESSOR
Discharge volutes
Impellers
Drive coupling

Impeller inlet
labyrinth seals
Shaft and
labyrinth seal
Journal bearing

Casing
(horizontally split
flange)

Thrust bearing
Compressor
discharge nozzle
Compressor
inlet nozzle

SURFACE FACILITIES CRUDE & GAS EVACUATION

ROTATING EQUIPMENT COMPRESSOR

SURFACE FACILITIES CRUDE & GAS EVACUATION

METERING

Fluid measurement commonly called metering

Purpose of metering
Contractual requirement
Production planning
Product quality control
Process control
Safety
Accuracy
Well testing deviations of 5% may be acceptable
Custody transfer deviations of 0.5% may be the
maximum allowed.
Dependent on two factors repeatability and
accurate determination of correction factors

SURFACE FACILITIES CRUDE & GAS EVACUATION

PIPELINE PIGGING

Reason for pigging

To clean and increase line efficiency

To locate obstructions and inspections of the line

To separate products

Corrosion control

Air purge and water removal

Meter proving

SURFACE FACILITIES CRUDE & GAS EVACUATION

PIPELINE PIGGING

QUESTIONS?