1Production EngineeringField Development Concept
2Course outcomes
At the end of the course the students should be able:
1. Identify and understand the different types of facility options used in oil and gas exploration and production.
2. To evaluate the types of facilities required for the efficient and economic means of producing oil and gas while meeting the appropriate regulatory / statutory requirements.
3Contents
1. Types of platforms
a. Fixed platforms
b. Manned / Unmanned
c. Mother / Satellite platforms
d. Platforms for marginal fields development.
2. Facilities requirements
a. Production facility
b. Well testing facility
c. Water handling facility
d. Power generation
e. Accommodation/Living quarters
f. IOR/EOR Water injection / Gas injection 3. Floating facilities
a. FPSO
b. FSO
4. Underwater facilities
a. Wellheads & protection jackets
5. Integrated development & production system
6. Energy consumption on offshore facilities
7. Q & A
41. Types of platforms
a. Fixed platforms
Definition:
A fixed platform is a structure that is used to support production facilities and/or other equipment (onshore/offshore) for a specified period of time. It may be piled or tied up to the ground /seabed or simply placed onsite due to its gravity.
A fixed platform may be removed when it has served its purposes or left in-situ after specific make-safe works been done.
51. Types of platforms
a. Onshore platforms
i. Cable tool drilling ii. Rotary drilling
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61. Types of platforms
a. Onshore platforms
i) Pumpjack (nodding donkey) ii) Rotating
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71. Types of platforms
a. Fixed offshore platforms
i) A Steel platform ii) A TLP
iii) A concrete gravity
81. Types of platforms
a. Fixed platforms (deepwater)
1. Types of platforms
a. Fixed platforms (deepwater)
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Spar
TLPSemi-
FPSFPSO (Wet)
Dry & Wet Trees Wet Trees Only
10
1. Types of platforms
a. Fixed platforms (deepwater)TLP
FPSO with Subsea Wells
Tanker
SubseaWells
FPSO
11
1. Types of platforms
a. Challenges for deepwater fields.
12
1. Example of platforms for deepwater
a. Kikeh (1300 m).
Five primary contract
packages: FPSO
DTU - Spar
Subsea Hardware
SURF
FTL
: MISC / SBM: Technip
: AkerKvaerner
: Technip
: SBM
13
1. Example of platforms for deepwater
a. Kikeh dry tree unit (DTU).
WATER DEPTH 1,300 m
25 RISER SLOT DTU
SPAR HULL 13,921 mt
32.3 m diamtre
142 m overall length
hard tank 67m long
WELLHEAD TOPSIDES 4,355 mt
MOORING SYSTEM 10 legs
driven pile anchors
chain / JSS / chain
TAD INTERFACE 4 x moorings, springers to Spar
RISER SYSTEMS Top tension risers
( SUPPLY ONLY ) Phase 1 : 4/1/1 prod / drill / WI
Phase 2 : 4/1 prod / WI
Phase 3 (Opt) : 6/2 prod / WI
HANDOVER 10 November 2006
14
1. Types of platforms
b. Manned / Unmanned
Definition:
A manned platform is usually occupied 24/7 by operators/working personnel and therefore provides accommodation / living quarters for them to stay in.
Unmanned platforms are those which did not provide living quarters for its working personnel and workers come and go on daily basis or on required basis only.
15
1. Types of platforms
c. Mother / Satellite platforms
Definitions:
A mother platform is the main platform that provides all the main facilities e.g. Production facilities, LQ, Power Generation, Communication Tower, etc. to the adjacent smaller platforms in a field that requires more than one platforms to fully develop and produced.
These smaller platforms only housed the wellheads for the production wells and test separators for well testing purposes are called the Satellite platforms.
16
1. Types of platforms
d. Platforms for marginal fields.
Definition:
Marginal fields are fields whose reserves are small
and required minimum facilities for their development
in order for them to be commercially viable. They
cannot used the conventional mega facilities &
infrastructures because of the huge cost that makes
the development and production unprofitable.
17
1. Types of platforms
d. Platforms for marginal fields.
Typical Platforms used are light-weight in nature,
easy to install and requires only a few wells to be
drilled and completed.
e.g. Tripod, Monopod and Wellhead Protection
Jackets.
18
2. Facilities requirements
a. Production facility consists of:
i. Production manifolds.
ii. Piping.
iii. Separators.
iv. Strainers / Scrubbers.
v. Heat Exchangers (Heaters / Coolers).
vi. Control Valves.
vii. Pumps.
viii. Instrumentation & Control.
ix. Water Treating facility.
x. Gas handling facility
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2. Facilities requirements
The offshore installation process
The offshore installation process
The offshore installation process
The offshore maintenance
24
2. Facilities requirements
b. Well testing facility
On each major platform there is also a well testing facility normally called test separator. It is functioning as a normal separator that separates water/oil/gas but has metering systems to measure the amount of water, oil, and gas individually. This test separator can be selectively tied in to the producing well for testing and monitoring its production performance. Connection is done through the production manifolds.
25
2. Facilities requirements
c. Water treating facility
The effluent water (produced together with the hydrocarbon) need to be removed as early as possible when it comes to surface to avoid corrosion and worst, reducing the capacity of the production facility. The water, before it can be thrown out to sea has to meet regulatory requirement normally between 15mg/l 50mg/l (even lower if onshore), depending on specific location offshore.
26
2. Facilities requirements
c. Water treating facility
Method Equipment type Approx. Min. Drop Size Removal
Gravity Separation Skimmer Tank & Vessels
API Separator, Disposal Piles
Skim Piles
100 150 Microns
Plate Coalescence Parallel Plate Interceptors
Corrugated Plate Interceptors
Cross-flow Separators
Mixed-flow Separators
30 50 Microns
Enhanced Coalescence Precipitators, Filter / Coalesces
Free-Flow Turbulent Coalesces
10 15 Microns
Gas Flotation Dissolved Gas, Hydraulic and
Mechanical Dispersed Gas
15 20 Microns
Enhanced Gravity Separation Hydro cyclones, Centrifuges 5 15 Microns
Filtration Multi-media Membrane 1+ Micron
27
2. Facilities requirements
d. Power generation
Electrical power generation is also a consideration for
offshore platforms. Electrical power is required for
lighting, to power fire water pumps, control systems
and many other equipment.
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2. Facilities requirements
d. Power generation
All power on offshore installations is generated locally
by gas turbines or diesel engines with low efficiency
(often as low as 20 %-25 % during the best
conditions) and high greenhouse gas emissions as a
result.
eg. The energy requirement for a BP project in deepwater Alaska, producing 220,000 b/d (FPSO), is between 80 100MW (Compression 44% and Water injection- 32%)
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2. Facilities requirements
d. Power generation
30
2. Facilities requirements
d. Power generation
31
2. Facilities requirements
d. Power generation
32
2. Facilities requirements
e. Accommodation/Living Quarters
For offshore platforms LQs is one important consideration in determining the facilities required for efficient and safe operations of the oil/gas production systems. Although there is an additional capital cost to be incurred for LQs requirement, the resultant operating costs (inclusive logistics) could be saved depending on the distance and number of people to man the platforms for safe and continuous operations at any one time during the fields life.
33
2. Facilities requirements
e. Accommodation/Living Quarters
Typical LQ capacity for Malaysian offshore operations
are between 80 120 men LQs.
During peak activities e.g. during Drilling campaign
additional space may be required to house the
essential personnel. These may be provided by the
drilling rig contractor or by hiring an accommodation
barge etc.
34
2. Facilities requirements
e. Accommodation/Living quarters
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2. Facilities requirements
f. IOR/EOR Water Injection / Gas Injection water Injection facility consists of pumping and water purifying and treatment units.
Gas Injection facility consists of gas conditioning/treating and gas compression units.
Space must be provided on the platform when these equipment are required.
36
3. Floating facilities
a. FPSO
(Floating processing, storage and offloading) is a ship like vessel that is used to receive life crude oil (or partly life) for further stabilization / separation, then provide space for storage until a cargo ship comes to receive the stabilized crude for export. FPSO has the facility to pump and transfer (offload) the crude oil into the cargo ship. An FPSO is usually anchored at a safe distance from the platforms within a producing field by SBM / SALM system.
37
3. Floating facilities
a. FPSO
(Floating processing, storage and
38
3. Floating facilities
b. FSO
(Floating storage and offloading) is also a ship like vessel but only receives a stabilized crude oil that has been processed at a platform. It functions entirely as storage and off loading facility. It is also anchored closed to the producing platforms (within an oil field) by a SBM / SALM system.
All crude is transferred to the FPSO/ FSO from the production platforms via a sub-sea pipeline.
39
3. Mooring Systems
40
4. Underwater facilities
a. Wellheads & Protection Jackets
Sometimes it is uneconomical to have platforms offshore to produce oil/gas at remote fields having small reserves or reserves found in ultra-deep seas. To exploit such a field individual well is drilled and completed underwater. Special wellheads are used for such wells and a protection jackets are used to protect the wellheads form anchors dropped /dragged from/by ships. The production are then hooked up to an FPSO or the nearby platform via a sub-sea pipeline. This type of facilities are common for deep sea productions.
41
4. Underwater facilities
a. Wellheads & protection Jackets
42
4. Underwater facilities
e.g. Kikeh (1300 m).
TYPICAL PRODUCTION CLUSTER
UTH
incoming umbilical
SDU
PRODUCTION
XTREEPRODUCTION
MANIFOLD
EFL Tronic connectors
EFL B
(UTH to SDU)
EFL B
(UTH to SDU)
EFL B
(SDU to SCM/xtree)
EFL A
(SDU to SCM/xtree)
HFL
(UTH to SDU)
HFL connector
(cobraheads)
HFL
(SDU to xtree)
HFL
(xtree to manifold)
rigid jumper
EFL
(xtree to manifold)
pipelines
pigging loop
43
5. Integrated development & production
system
This is a platform complex housing the required
facilities for the oil/gas production. The production
(wellheads), separations, compression, Pumping,
Power Generation, Flare boom and LQs may be
housed on a single platform (huge) or a few individual
smaller platforms but linked by bridges.
44
5. Integrated Development & Production
System
The integrated components may be added-on later to
meet the field development requirements
45
6. Energy consumption on offshore
facilities
An offshore oil and gas facility provides excellent
opportunities of energy consumption studies
Not many studies have been carried out in the past
due to the lack of drive and commitment from the oil
and gas organisations
The general perception surrounding the energy abundance of the E&P activities is partly responsible for the lack of enthusiasm
Recent regulatory requirements have forced major oil
and gas companies to have a re-look at the energy
issues surrounding their E&P activities
46
6. Energy consumption on offshore
facilities
47
6. Energy consumption on offshore
facilities
48
6. Energy consumption on offshore
facilities
49
6. Energy consumption on offshore
facilities
50
6. Energy consumption on offshore
facilities
The current and anticipated future concerns with
regard to energy consumption, wastage and
efficiencies include:
Flaring
Venting
Power production
energy efficiencies
Energy consumption and wastage from the
production processes
51
6. Energy consumption on offshore
facilities
The energy balance of an offshore production facility
can be generally assumed as follows:
Diesel
Natural gas
Flaring/venting
Waste heat/losses
Excess supply
Alternative energy??
52
6. Energy consumption on offshore
facilities
Solutions include:
Regulatory requirements:- CO2 taxation (Norway
introduced the worlds highest CO2 tax in 1994 @ approx. $20/barrel of oil)
New, low energy extraction and transportation
technology for E&P (gas consumption can contribute
to 83% of the emissions and flaring contributes
another 10%) ie. Electric wireline, horizontal drilling
Energy recovery from production and utility processes
ie. CHP, co-generation
Alternative energy options
Inter-platform power distribution
53
7. Q & A