Surface Facilities Design

CHOPS Workshop
Surface Facilities Design – Main topics
 Surface Facilities design considerations
 Process Scheme
 Tanks Design
 Sand Handling and Disposal
 Surface Layout: Tanks, Lines, Power, Fiber Optics,
Flaring, etc.
 Pads and Access Roads Specifications
 Measuring Qo, Qw, Qg, Qs.
 Tools and Equipment: Local Availability and
Canadian.
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Surface Facilities Design Considerations
 Objective:
– To handle CHOPS pilot test wells fluids
– To measure produced fluids, gas and sand.

 Considerations:
– Use only proven technology
– Design to be as simple as possible
– Foamy oil behavior considered (expansion factor: 5)
– Facilities optimization is not intended at this stage
– Facilities design and pump rates based on estimated stable
production of 400 BPD of EHO.
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Process Scheme

DILUENT
INJECTION VENT
(OPTIONAL)

DEGASSING FLAME
BOOT DILUENT ARRESTOR
INJECTION
GAS GATHERING

PCP
HEATER
PUMP
DCO TRUNKLINE

WASH TANK SURGE TANK

CASING
GAS
SAND TO CTF

CHOPS WELL TEMPORARY

SAND STORAGE VACUUM
TRUCK

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 Tank design
TANKS:
- API 12F standard shop
fabricated tanks
- 750 barrels capacity
- 4.7 m Ø x 7.3 m height
- Immersion Type Heater
- Duty: 286 KW
5.9 HR SLACK FOR PRODUCTION
INTERFACE FOR 7HR
CONTACT TIME ACCUMULATION - Sampling points
IN CONTINGENCIES

DEGASSING BOOT:
- Wash tank with internal
Degassing boot.
WATER PAD
2 HR ACCUMULATED OIL - 0.6m diameter
ACCUMULATED SAND
AND WATER
FOR PUMPING
- 3 internal plates.
M
DEAD SAND OIL + WATER
DEAD VOLUME

WASH TANK SURGE TANK

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Sand Handling and Disposal
 Sand separation at wash tank promoted by:
– Fluid heating up to 80oC to reduce viscosity
– Water bath to improve sand separation
– 7 hours residence time at normal liquid level.

 Sand removal using an auger (screw)

 Temporary sand storage and handling facility

 Transportation using Super Vacuum Truck

 Sand disposal is under investigation, possibility to mix

CHOPS sand with drilling cuttings at CTF for treatment and
disposal.

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Surface layout: interconnection lines for
producer wells

Access road

Diluent pipeline
Typical
Existing DCO pipeline

cluster Gas to Gas gathering system

CHOPS
YC Fiber Optic cable well
Power line pad

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Surface layout: interconnection lines for
observation wells

Access road

Existing Typical
Fiber Optic cable
observation
cluster well
YC Power line ?
pad

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Pads and Access Roads Specifications
 Pads:
– Estimated Pad area: 70 m x 70 m
• Area required for well drilling and servicing: 70m x 70m
– Load capacity: 2.5 kg/cm2
– Material type: Asphalt

 Access Road:
– Width: 6m
– Load capacity: 2.5 kg/cm2
– Material Type: Asphalt
– Maximum slope: 7%
– Radius of curvature: 60m

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Preliminary Plot plan
(70m x 70m) (70m x 70m) Wells
None
affected Asphalt
area (affected area)

Tanks &
(70m x 90m) Auxiliaries area
200 m.
250 m.

Pipe way

Access road

(70m x 70m) (70m x 70m)

200 m.
250 m.
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Surface layout: Tentative pad location

NEW CHOP WELL PADS








New pipe way &
cable route New access road 11
 Measuring Qo, Qw, Qg, Qs.

SP Sampling point Sand: wellhead

sampling
and sand
M Meter M VENT removed
from wash tank.
DILUENT
INJECTION Water:
sampling at
SP
GAS GATHERING

HEATER wellhead
SP SP M DCO TRUNKLINE (BS&W).
M
PCP Gas: casing gas
PUMP
M WASH TANK SURGE TANK and
CASING vent gas meters.
GAS SP SAND TO CTF

CHOPS WELL TEMPORARY Oil: mass flow

VACUUM
SAND STORAGE
TRUCK
meter
at tank
discharge

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Tools and Equipment: Local Availability and
Canadian.
 Local or typical availability (none specialized):
– Engineering
– Tanks, pumps, piping and civil works
– Electrical and instrumentation equipment.
– Super Vacuum Trucks

 Canadian (specialized)
– Engineering consultancy
– Auger design and fabrication

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Production / CHOPS Pilot Project-Surface Facilities Design / Luciano Da Costa
September 7th, 2005
Example of temporary
sand disposal facility
Vacuum truck
connection
Super Vacuum truck equipped with 8” hose.
 Super vacuum truck
•Discharge by gravity helped by
vibration mechanism
•Volumetric capacity: 110 Bls.
•Suck and transport liquids and solids.
•Suction hose: 8” and 4”
•Suction capacity: 2500 m3/hr
•Suction pressure: -0.91 barg

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Example of Canadian tanks and auger

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Estimated well production
Oil prod Oil cum Sand cut Sand Sand Sand cum
Month Oil (bpd) (bbl) (bbl) (% vol) prod (bbl) prod (m3) (m3)
1 100 3000 3000 10 300 48 48
2 200 6000 9000 10 600 96 144
3 300 9000 18000 5 450 72 216
4 400 12000 30000 4 480 76.8 293
5 400 12000 42000 3 360 57.6 350
6 400 12000 54000 2 240 38.4 389
7 400 12000 66000 1 120 19.2 408
8 400 12000 78000 1 120 19.2 427
9 400 12000 90000 1 120 19.2 446
10 400 12000 102000 1 120 19.2 466
11 400 12000 114000 1 120 19.2 485
12 400 12000 126000 1 120 19.2 504
13 400 12000 138000 1 120 19.2 523
14 400 12000 150000 1 120 19.2 542
15 400 12000 162000 1 120 19.2 562
16 400 12000 174000 1 120 19.2 581
17 400 12000 186000 1 120 19.2 600
18 400 12000 198000 1 120 19.2 619
19 400 12000 210000 1 120 19.2 638
20 400 12000 222000 1 120 19.2 658
21 400 12000 234000 1 120 19.2 677
22 400 12000 246000 1 120 19.2 696
23 400 12000 258000 1 120 19.2 715
24 400 12000 270000 1 120 19.2 734
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 Process Scheme: option with 1 tank
DILUENT
INJECTION
(OPTIONAL)

VENT

DEGASSING FLAME
BOOT ARRESTOR

DILUENT
INJECTION
GAS GATHERING

PCP
PUMP
DCO TRUNKLINE

HEATER

M
CASING
SAND TO CTF
GAS
WASH TANK
CHOPS WELL TEMPORARY VACUUM
SAND STORAGE TRUCK
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Tanks Design: option with 1 tank
Tank Degassing Boot
-Atmospheric storage tank -Internal or external
-Size: 4.7m x 15.5m -Diameter: 0.6m (24”)
8HR SLACK FOR PRODUCTION (15’-6” x 51’) -3 internal plates
ACCUMULATION
IN CONTINGENCIES -Shop fabricated

2 HR ACCUMULATED OIL Vent

AND WATER
FOR PUMPING

Degassing Boot
INTERFACE FOR 8 HR
CONTACT TIME Electrical Electrical
heater heater

WATER PAD
ACCUMULATED SAND
DEAD SAND
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