OffshoreOilandGas ProductionSystems

OFFSHOREPRODUCTIONSYSTEMASCHEMATIC

DATA/SCADA

SBM
POWER UMBILICAL(DATA/WELLCONTROL) WELLFLUID INJ.WATER W LIFTGAS WELLS WELLTESTING PRODNOPTIMIZATION WELLCONTROL WELLSERVICING TELEMETRY/SCADA WELLFLUID (OIL/GAS/WATER) WELLS/CONNECTEDWELLP/F SEPARATIONMODULEOIL/GAS/WATER LIFTGAS

TANKER

WELLP/F'S

INJETCTIONWATER

PROCESS PLATFORMS

OILTOREFINERY OIL GAS ONSHORE TERMINALS GASTOCONSUMERS

WELLS
OILPRODUCERS GASPRODUCERS INJECTIONWELLS

GASCOMPRESSIONANDDEHYDRATIONMODULE SEAWATERTREATMENTFORWATERINJECTION PRODUCEDWATERTREATEMENTMODULE POWERGENERATION UTILITIESWATER/SUPPLIES LIVINGQUARTERS DRILLING/WELLSERVICINGRIGMODULE

THEMAJORELEMENTSOFOFFSHORE PRODUCTIONSYSTEM
WELLS(SUBSEA/PLATFORMWELLS) WELLPLATFORMS/WELLSERVICINGRIGS FEEDERSUBSEAPIPELINES PROCESSINGPLATFORMS EXPORTPIPELINESFOROIL/GAS TANKERSFOREVACUATIONOFOIL.

Weshalldiscussabout PLATFORMS WELLHEADPLATFORMS WELLS PROCESSINGSYSTEM NEWTECHNOLOGIES

TYPESOFOFFSHOREPLATFORMS

WATERDEPTHANDTYPEOFPLATFORM

Oilplatforms
Anoilplatformoroilrigisalargestructureusedtohouse workersandmachineryneededtodrilland/orextractoiland naturalgasthroughwellsintheoceanbed. Dependingonthecircumstances,theplatformmaybeattached totheoceanfloor,consistofanartificialisland,orbefloating. Generally,oilplatformsarelocatedonthecontinentalshelf, thoughastechnologyimproves,drillingandproductionin deeperwatersbecomesbothfeasibleandprofitable. Atypicalplatformmayhavearoundthirtywellheadslocatedon theplatformanddirectionaldrillingallowsreservoirstobe accessedatbothdifferentdepthsandatremotepositionsupto 5miles(8kilometres)fromtheplatform. Manyplatformsalsohaveremotewellheadsattachedby umbilicalconnections,thesemaybesinglewellsoramanifold centreformultiplewells.

FIXEDPLATFORMS
Theseplatformsarebuiltonconcreteand/orsteellegs anchoreddirectlyontotheseabed,supportingadeck withspacefordrillingrigs,productionfacilitiesand crewquarters. Suchplatformsare,byvirtueoftheirimmobility, designedforverylongtermuse. Varioustypesofstructureareused,steeljacket, concretecaisson,floatingsteelandevenfloating concrete. Steeljacketsareverticalsectionsmadeoftubularsteel members,andareusuallypiledintotheseabed. Concretecaissonstructures,oftenhaveinbuiltoil storageintanksbelowtheseasurfaceandthesetanks wereoftenusedasaflotationcapability,allowingthem tobebuiltclosetoshoreandthenfloatedtotheirfinal positionwheretheyaresunktotheseabed. Fixedplatformsareeconomicallyfeasiblefor installationinwaterdepthsuptoabout1,700feet(520 m).

FixedPlatform

SemisubmersiblePlatform
Theseplatformshavelegsofsufficient buoyancytocausethestructuretofloat, butofweightsufficienttokeepthe structureupright. Semisubmersiblerigscanbemovedfrom placetoplace;canbeballastedupordown byalteringtheamountoffloodingin buoyancytanks; Theyaregenerallyanchoredbywithchain, wireropeand/orpolyesterropeduring drillingoperations,thoughtheycanalsobe keptinplacebytheuseofdynamic positioning. Semisubmersiblescanbeusedinwater depthsfrom200to10,000feet(60to 3,050m).

JackupPlatforms
Jackups,asthenamesuggests,areplatforms thatcanbejackedupabovetheseausinglegs whichcanbeloweredlikejacks. Theseplatformsaretypicallyusedinwater depthsupto400feet,althoughsomedesigns cangoto550feetdepth. Theyaredesignedtomovefromplaceto place,andthenanchorthemselvesby deployingthelegstotheoceanbottomusinga rackandpiniongearsystemoneachleg.

CompliantTowers
Theseplatformsconsistofnarrow, flexibletowersandapiledfoundation supportingaconventionaldeckfor drillingandproductionoperations. Complianttowersaredesignedto sustainsignificantlateraldeflections andforces,andaretypicallyusedin waterdepthsrangingfrom1,500and 3,000feet(450and900m).

Drillships
Adrillshipisamaritimevesselthathas beenfittedwithdrillingapparatus.Itis mostoftenusedforexploratorydrillingof newoilorgaswellsindeepwaterbutcan alsobeusedforscientificdrilling.Early versionswerebuiltonamodifiedtanker hull,butpurposebuiltdesignsareused today.Mostdrillshipsareoutfittedwitha dynamicpositioningsystemtomaintain positionoverthewell.Theycandrillin waterdepthsupto12,000feet(3,660m).

Floatingproductionsystems
FPSOsarelargeshipsequippedwith processingfacilitiesandmooredtoalocation foralongperiod. Themaintypesoffloatingproductionsystems are: FPSO (floatingproduction,storage,and offloadingsystem), (floatingstorageandoffloading system),and (floatingstorageunit).

FSO

FSU

Theseshipsdonotactuallydrillforoilorgas.

FPSOANDSUBSEAWELLS

Tensionlegplatform
TLPsconsistoffloatingrigstetheredtothe seabedinamannerthateliminatesmostofthe verticalmovementofthestructure. TLPSareusedinwaterdepthsuptoabout6,000 feet(2,000m).The"conventional"TLPisa4 columndesignwhichlookssimilartoa semisubmersible. ProprietaryversionsincludetheSeastarand MOSESminiTLPs;theyarerelativelylowcost, usedinwaterdepthsbetween600and4,300 feet(200and1,300m). MiniTLPscanalsobeusedasutility,satelliteor earlyproductionplatformsforlargerdeepwater discoveries.

SPARPlatforms
SparsaremooredtotheseabedliketheTLP,but whereastheTLPhasverticaltensiontetherstheSpar hasmoreconventionalmooringlines. Sparshavebeendesignedinthreeconfigurations: the"conventional"onepiececylindricalhull,the "trussspar"wherethemidsectioniscomposedof trusselementsconnectingtheupperbuoyanthull (calledahardtank)withthebottomsofttank containingpermanentballast,andthe"cellspar" whichisbuiltfrommultipleverticalcylinders. TheSparmaybemoreeconomicaltobuildforsmall andmediumsizedrigsthantheTLP,andhasmore inherentstabilitythanaTLPsinceithasalarge counterweightatthebottomanddoesnotdepend onthemooringtoholditupright. Italsohastheability,byuseofchainjacksattached tothemooringlines,tomovehorizontallyoverthe oilfield. Worldsdeepestspar:Eni'sDevil'sTowerislocated in5,610feet(1,710m)ofwater,intheGulfof Mexico;however,whenShell'sPerdidoSparis installed,itwillbethedeepestat8,000feet(2,438 m

Maintenanceandsupply
Atypicaloilproductionplatformisselfsufficientinenergyandwaterneeds, housingelectricalgeneration,waterdesalinatorsandallofthe equipment necessarytoprocessoilandgassuchthatitcanbeeitherdelivereddirectly onshorebypipelineortoaFloatingStorageUnitand/ortankerloadingfacility. Elementsintheoil/gasproductionprocessincludewellhead,production manifold,Productionseparator,glycolprocesstodrygas,gascompressors, waterinjectionpumps,oil/gasexportmeteringandmainoilline pumps. Allproductionfacilitiesaredesignedtohaveminimalenvironmentalimpact. LargerplatformsareassistedbysmallerESVs(emergencysupport vessels)that aresummonedwhensomethinghasgonewrong,e.g.whenasearchand rescueoperationisrequired. Duringnormaloperations,PSVs(platformsupplyvessels)keeptheplatforms provisionedandsupplied,andAHTSvesselscanalsosupplythem, aswellas towthemtolocationandserveasstandbyrescueandfirefightingvessels.

Crew
Thesizeandcompositionofthecrewofanoffshore installationwillvarygreatlyfromplatformtoplatform. Becauseofthecostintensivenatureofoperatinganoffshore platform,itisimportanttomaximiseproductivitybyensuring workcontinues24hoursaday. Thismeansthatthereareessentiallytwocompletecrewson boardatatime,onefordayshiftandtheotherfornightshift. Crewswillalsochangeoutatregularintervals,nominallytwo weeks.

Essentialpersonnel
Notallofthesepersonnelarepresentoneveryplatform,onsmallerplatformsworkerswillberesponsible forseveralareas.Thenamesshownarenotindustrywide. * * * * * * * * * * * * * * * * OIM(offshoreinstallationmanager)istheultimateauthorityduringhis/hershiftandmakesthe essentialdecisionsregardingtheoperationoftheplatform. OperationsTeamLeader(OTL) OffshoreOperationsEngineer(OOE)istheseniortechnicalauthorityontheplatform PSTLorOperationscoordinatorformanagingcrewchanges DynamicPositioningOperator,navigation,shiporvesselmaneuvering(MODU),stationkeeping, fireandgassystemsoperationsintheeventofincident 2ndMate Meetsmanningrequirementsofflagstate,operatesFastRescuecraft,cargoops,fire teamleader. 3rdMate Meetsmanningrequirementsofflagstate,operatesFastRescuecraft,cargoops,fire teamleader BallastControlOperator_alsofireandgassystemsoperator Craneoperatorstooperatethecranesforliftingcargoaroundtheplatformandbetweenboats. Scaffolderstorigupscaffoldingforwhenitisrequiredforworkerstoworkatheight. Coxwainsformaintainingthelifeboatsandmanningthemifnecessary. Controlroomoperators EspeciallyFPSOorProductionplatforms. Cateringcrewwillincludepeopletaskedwithperformingessentialfunctionssuchascooking, laundryandcleaningtheaccommodation. Productiontechsforrunningtheproductionplant HelicopterPilot(s)liveonsomeplatformsthathaveahelicopterbasedoffshore.Thehelicopter flightcrewtransportsworkerstootherplatformsortoshoreon crewchanges. maintenancetechnicians(instrument,electrical,mechanical)

Essentialpersonnel ONGCSystem
MANAGERS:
OFFSHOREINATALLATIONMANAGER PROCESSMANAGER MAINTENANCEMANAGER WELLPLATFORMMANAGER HSEMANAGER

TEAMS
Processcontrolroomoperators Mechanical/Electrical/Instrumentationteam StaticEquipmentmaintenanceteam Wellheadteams Pipelinemaintenanceteam SkilledandUnskilledtechnicians

Incidentalpersonnel
* Drillcrewwillbeonboardiftheinstallationisperforming operations.Adrillcrewwillnormallycomprise: oToolpusher oRoughnecks oRoustabouts oCompanyman oMudengineer oDerrickhand oGeologist * Wellservicescrewwillbeonboardforwellwork.Thecrewwill normallycomprise: oWellservicessupervisor oWirelineorcoiledtubingoperators oPumpoperator drilling

Risks
Thenatureoftheiroperation extractionofvolatilesubstances sometimesunderextremepressureinahostileenvironment has riskandaccidentsandtragediesoccasionallyoccur.InJuly1988, 167peoplediedwhenOccidentalPetroleum'sPiperAlphaoffshore productionplatform,onthePiperfieldintheNorthSea,exploded afteragasleak.Theaccidentgreatlyacceleratedthepracticeof providinglivingaccommodationsonseparaterigs,awayfromthose usedforextraction. However,thiswas,initself,ahazardousenvironment.InMarch 1980,the'flotel'(floatinghotel)platformAlexanderKielland capsizedinastormintheNorthSeawiththelossof123lives. Giventhenumberofgrievancesandconspiracytheoriesthat involvetheoilbusiness,andtheimportanceofgas/oilplatformsto theeconomy,platformsarebelievedtobepotentialterrorist targets.Agenciesandmilitaryunitsresponsibleformaritime Securityoftentrainforplatformraids.

Ecologicaleffects
InBritishwaters,thecostofremovingallplatformrigstructuresentirelywasestimatedin 1995at$345billion,andthecostofremovingallstructuresincludingpipelines asocalled "cleansea"approach at$621billion. Furthereffectsaretheleachingofheavymetalsthataccumulate inbuoyancytanksinto water;andrisksassociatedwiththeirdisposal. Therehasbeenconcernexpressedatthepracticeofpartiallydemolishingoffshorerigsto thepointthatshipscantraverseacrosstheirsite;therehavebeeninstancesoffishery vesselssnaggingnetsontheremainingstructures. ProposalsforthedisposalatseaoftheBrentSpar,a449fttallstoragebuoy,wasforatime in1996anenvironmentalcauseclbreintheUKafterGreenpeaceoccupiedthefloating structure.Theeventledtoareconsiderationofdisposalpolicy intheUKandEurope. IntheUnitedStates,MarineBiologistMiltonLovehasproposedthatoilplatformsoffthe Californiacoastberetainedasartificialreefs,insteadofbeingdismantled(atgreatcost), becausehehasfoundthemtobehavensformanyofthespeciesoffishwhichareotherwise decliningintheregion,inthecourseof11yearsofresearch.Loveisfundedmainlyby governmentagencies,butalsoinsmallpartbytheCaliforniaArtificialReefEnhancement Program. IntheGulfofMexico,morethan200platformshavebeensimilarlyconverted.

Un-manned Platforms

Normallyunmannedinstallations.
Theseinstallations(called WellheadPlatforms),are smallplatforms,consistingof littlemorethanawellbay, helipadandemergency shelter. Theyaredesignedtooperate remotelyundernormal operations,onlytobevisited occasionallyforroutine maintenanceorwellwork.

WELLHEADPLATFORMS
Generally4leggedunmannedplatforms Consistsof4decks,spiderdeck,cellardeck,maindeckandhelideck PersonnelvisittheplatformforWelltestingandothermaintenance activities. Mayhave3to32wells(ProducersandInjectors),oneverticalwelland othersdirectionalandreachingoutindifferentdirectionupto 6km fromtheplatform. WellsaredrillednormallybyJackupRigsthatdockwiththeplatform. Wellservicing(workover)isdoneeitherbyJackuprigsorbyModular Rigsthatareassembledovertheplatform.
JACKUPRIGDOCKEDONWELLPLATFORMFOR DRILLING/WELLSERVICING SOLARPANELSPOWERTHEWELLPLATFORMS

FacilitiesinWellPlatforms
Wells ProductionManifoldtoreceivewellfluidfromallthewells LiftgasManifoldforfeedingliftgastowellalongwithInjectiongas regulation/Controlandmeasurementsystem. WImanifoldforfeedinginjectionwatertoWIwellsalongwithmeteringsystem. TestmanifoldandTestseparatorandassociatedmeasurementsystemforOil,Gas andWater. WellcontrolPanel(SDP) Instrumentgassystem RTUandSCADA Batterypack,Solarpowerpanel. SubsealinescarrywellfluidfromtheplatformtotheProcessplatform Also,LiftgasandInjectionwaterisbroughtinbysubsealines fromProcess Platform. EmergencyGenset. FirewaterpumpsandFirefightingsystem. HCGasdetectors ESD/FSDsystem Crane.

SDP
Pneumatic control panels are designed to monitor crucial wellhead safety parameters. Theyprovidesequentialstartupandsafeshutdownofproduction wells. Inremoteunmannedwellheadplatformsproducedgasisusedasthemediuminsidethe control panel. Easy availability of pneumatic power source makes pneumatic controls a desirablechoice. Thepneumaticshutdownpanelisdesignedasacentralprotection unitforoverallprotection oftheinstallation.Threelevelsofprotectionforpersonnel,productionwellsandsurface facilitiesareenvisaged.Thusapanelconsistsof; a)Fireandgasleakageprotectionsystem: Anygasleakageisautomaticallydetectedand appropriate shutdown action initiated to prevent formation of combustible mixture. All sources of ignition are also shutdown. Any eruption of fire is detected and appropriate shutdownandsuppressionactioninitiated. b)SurfaceFacilityProtection:Asafetyanalysisorhazardousoperability(HAZOP)analysisof surfacefacilitiesincludingrotaryandprocessequipmentsiscarriedout.Allpossiblehazards, interrelationbetweenvariousparametersare identified and listed. Thefunctionalchartthus evolvedistheSAFE(SafetyAnalysisandFunctionEvaluation)chart.TheSAFEchartformsthe basisfordesignofpanelinsurfacesafetyprotection. c)Wellcontrol&Protection: Amajorfunctionofthewellheadshutdownpanelistocontrol thewellthroughthesurfaceandsubsurfacesafetyvalves.Theinterrelationsbetweenvarious valvesarewelldefinedandtheirsequentialoperationestablished.

WELLCONTROLSCHEMATIC
FSD FIRESHUTDOWN FUSIBLE PLUGLOOP

WELL XMAS TREE

SSV SUFRACE SAFETYVALVE PNEUMATICPRESSURETOSSV

HC DETECTORS

PNEUMATICSUPPLY GISHUTDOWN VALVE

PRESSURESWITCH HIGHLOW

ESD
HYDRAULICPRESSURETOSSSV

RADIO SIGNAL

WELL CONTROL SDP

WELLFLOW

REMOTE CONTROL

RTU(REMOTETELEMETRY UNIT)

PNEUMATICSUPPLY

LIFTGAS

SURFACECONTROLLEDSUBSURFACE SAFETYVALVE 150 MFROMP/FDECK

WELLCONTROL
WellsclosebySSV(SurfaceSafetyValve)andSSSV (SubsurfaceSafetyValve)whenabnormal conditionsexists. AbnormalconditionsmaybeHigherPressuresinthe flowlines,Fire. WellscanalsobeclosedremotelyfromProcess platforms/ShorethroughSCADAwiththehelpof RTU.

SMARTWELLHEADPLATFORMS
ProvidesWellheadrealtimedata. ProvideRealtimeMonitoringandControlofUnmanned Platformsandwells. ProvidesminimumHumanInterventionindaytodayoperations ProvideStabilisedproductionandTransportationsprocessalong withOptimisations ProviderealtimedataConsolidation,Recordingandstoragefor theanalysisforfutureevaluations. Reducethedelayindecisionmakingviaonlinemeasurementsof criticalparameterssuchasWatercut,GasRatesetc.

MajorElementsofSMARTplatform
Instrumentationonwellhead. AutomatedWelltestingusingRemotelyOperatedMultiSelector Valveinwellplatform. AutomationsystemtoMonitorandOptimiseProduction. RemoteLiftGasoptimization. Integrationofdifferentautomationsystemtoensuredata consolidationatcentralfacilities. WANCommunication:Radio,V satatoffshorewellheadplatform.

WELLS
Producers Selfflow,GasliftedandESP. Injectors Subseawells: DryTree,WetTreewells. Directionalwells Horizontalwells ERDWells Multilateralwells Intelligentwells

GasLiftedwells

SELFFLOWINGANDGASLIFTEDWELLS

ELECTRICALSUBMERISBLEPUMPS(ESP)WELLS

VERTICAL WELL
30 20

DEPTH

13 3/8

OIL & GAS GAS 2050 PSI

9 5/8 OIL PRESSURE

LI LII SI LIII

1350

1800 psi

7 LINER

DIRECTIONALWELL
30/26 20

13 3/8
LI LII SI LIII

9 5/8 7
OIL

HORIZONTAL WELLS

PRODUCING ZONE

Drain hole

MULTI-LATERAL WELL MULTILATERALWELL

FISHBONEMULTILATERALWELL

Manyribsbranchoffthemainwellbore.Thepathofoiltothewellisshorter througharibthanthroughtherock,bothinhomogeneous sandsandevenmorein heterogeneoussandswithbarriersandbaffles.Ribscanbeadded toanylateral.

WELLMONITORINGANDCONTROL RTU/SCADA

SCADA FORWELLMONITORING,CONTROLAND PRODUCTIONOPTIMIZATION

SUPERVISORYCONTROLANDDATAACQUISITION GathernecessaryDATAfromaREMOTELYLOCATED Oil/GaswellandWellPlatformwiththehelpofField Transmitters&RTUandsendittotheDATA GATHERING&ANALYSISpoint.

SCADA OVERVIEW
RADIOLINK

LIFTGAS
DATAGATHERINGAND

INTERPRETATION
INJECTIONWATER

WELLFLUID
WELLPLATFORM PROCESSPLATFORM

SCADAMETHODOLOGY
WELLHEAD PRESSURE& TEMP

OIL,GAS WATER FLOWRATES

SSV OPEN/CLOSE STATUS

SSV

GAS/OIL
GIACV

TOGROUPHEADER

GASINJ. PRESSURE

LIFTGASFROM PROCESS PLATFORM

SSSV OPEN/CLOSE STATUS

PRODUCTION TUBING

LIFT GAS RATE

PARAMETERSAVAILABLEFOR MEASUREMENTINANOILWELL ONGASLIFT

GLV
ANNULUS

BHP

SCADA ASCHEMATIC
ANALOGSIGNALSIN RANGEOF15V(420mA)

MONITORINGPRESSURE,TEMPetcATSANDFACE, WELLHEADORELSEWHEREWITHTHEHELPOFSENSORS

RTUINSTALLEDONWELLPLATFORM (ANALOGTODIGITALCONVERSION)
RADIOLINK

INTERFACINGSOFTWARE

INTERPRETATIONOFSTOREDDATA

DATAGATHERINGSTATION (USUALLYAPROCESSPLATFORM)

DECISIONMAKINGPROCESS

MAJORBENEFITSOFSCADA
24hrsonlinemonitoringofwellstatusandflow,liftparametersfrom ProcessComplexaswellasfromonshorecontrolcentre. HistoricalDataandtrendinghelpsinTroubleshooting. Abilitytoclosewellsremotelyduringemergency. BetterProductionoptimizationofindividualwells InstantalertsincaseofWellclosures,ESD,FSDandcontrolpanelfailure OptimumutilizationofManpowerforattendingtowellproblems Reductioninnumberofphysicalvisitstowellplatformsresultingin optimizationofHelicoptersorties. Toobserveslugginginpipelines. Liftgasallocationforeachwell.

MONITORINGOFWELLPLATFORMUSINGSCADA THISISACCESSIBLEFROMANY DESKTOPCOMPUTERINONGCLANNETWORK.

MIMICDISPLAY

MONITORINGOFWELLPLATFORMUSINGSCADA

STATUSDISPLAY

MONITORINGDIFFERENTALARMSWITHTHEHELPOFSCADA

SCADAHELPSINLIFTGASALLOCATION/PRODUCTIONALLOCATION

TRENDINGOFGIPRESSURE,MLGIP,TEMPERATURE,LIFTGASRATEHELPS INKEEPING WELLSFLOWINGATITSOPTIMUM24x7

WELLAUTOMATION

DESIGNFORAUTOMATEDCONTROLSYSTEMFORGLOPTIMIZATION

FTHP
PROD.CHOKE

FLOWSENSORS OWG

WHT

GAS/OIL

REMOTELYCONTROLLEDGIACV

CONTROLSIGNAL FORACVTO ADJUSTTHELIFT GASFLOW

AUTOMATED FEEDBACK CONTROLERTO MAINTAINTHEFIXED LIFTGASRATE

GASFLOW REQUIREDFOR OPTIMUM PRODUCTION

ALGORITHMFORGAS LIFTOPTIMIZATION (BASEDONGASIN OILOUTCURVE)

LIFTGASFROMPROCESS PLATFORM

PRODUCTIONTUBING

GIP LIFTGAS FLOW

GLV

ANNULUS

BHP BHT
RESERVOIR

OnlineMonitoringandRemotecontrolofInjectionGas
SP
FLOW COMPUTER With Flow control card

RTU

TT I/P
RTU

FCV

GI HEADER

PT

FT

TE

VB FE
CVA

Gas injection to well

FC is accessed via SCADA from the process complex and Injection gas Rate is monitored and adjusted, if required, remotely.

REMOTEOPTIMIZATIONOFWELLUSING FCMPFMSET SP
RTU
FLOW COMPUTER With Flow control card

TT I/P

FCV

RTU

GI HEADER

PT

FT

TE

MPFM
VB FE
CVA

Gas injection to well

WELL
To header

Injection gas is remotely monitored, controlled via RTU-FC-FCV through SCADA One well is diverted via MPFM and Production rates available through SCADA at Process PF. Well can be tested and Optimized REMOTELY for different Injection gas rates by changing the set point in FC-I/P-FCV Loops via SCADA.

SMARTonline24x7monitoringandOptimizationofeachwellUsing GasFlowComputer CompactGLCCSeparator CoriolisMassflowMeter Set.

GLCC(GasLiquidCylindrical Cyclonic)Separator

RTU
InjectionGas controlled Remotelythrough SCADAbyFCFCV (Flow computer)

CoriolisMass FlowMeter

WELL RTU ToHeader

(

JackupRigdockedinaWellheadplatform

PROCESSINGINOFFSHORE PROCESSPLATFORMS
SEAWATERTREATMENT ANDINJECTION LIVINGQUARTERS SEPARATIONANDCRUDE PUMPING

GASCOMPRESSION& DEHYDRATION

BRIDGECONNECTED WELLPLATFORM

PROCESSES
3PhasewellfluidisreceivedfromWells/WellPlatformsandprocessedat LargeProcessPlatformsgenerallyconsistingofthefollowingfourMajor ProcessingModules

Separation(Oil,GasandProducedwater)&Oildispatch GasCompression&dehydration ProducedWaterConditioning Seawaterprocessing&injectionsystem

Theseprocesscomplexeswillalsohavethefollowing:
Firedetection&Suppressionsystem PowerGeneration Wellservices/drillingModules WaterMaker/Utilities/SewageTreatment LivingQuarters

SEPARATION

SEPARATION

Oil,GasandWaterisseparatedfromtheWellfluid. WellFluidfromvariousWells/WellPlatforms/SubseaManifoldreachestheprocess complexviasubseapipelinesandrisersandisfurtherprocessed inmorethanone train.

EachTrainwillnormallyconsistofaProductionManifold,Well fluidheater,Inlet Separator,CrudeoilManifold,Crudeoilheater,SurgeTanksand MOLPumps. WellFluidisreceivedintheProductionManifold.DemulsifierChemicalisdozedin ProductionmanifoldtopromotebreakingupofWaterOilemulsion ThenitisheatedinwellfluidheaterwithHotoilFlowinginShellSideandwellfluid intubeside.ThisheatingenablesbetterseparationofoilandwaterinInlet Separator.

TheWellFluidfromWellfluidheaterreachesInletSeparator.

InletSeparator FirstStageSeparation
InletSeparatorisavesselinwhich3phaseseparationofwellfluidintoOil,Gasand Wateroccurs. Separationisbygravitymainlyassistedbychemicalandheat.Residencetimeinthe vesselisanimportantcriteriaforbetterseparation. SeparatedGasisroutedtoGascompressionanddehydrationModule. CompressedgasissenttotheLiftgasnetworkforliftingtheproducersandexcess gasisexportedviapipelinestoshore. Separatedoilflowstotheoilmanifold. SeparatedwaterflowstoProducedwaterconditioningunit. Fromoilmanifoldcrudeoilflowstocrudeoilheaterinwhichcrudeoilisheatedwith hotoil.Thisenhancestheseparationofoil&waterinSurgeTanks(secondstage separation). Demulsifierchemicaldozedinoilmanifoldfurtherpromotesthebreakingofwater Oilemulsion.

PFD OIL,GAS,WATERSEPARATION

SurgeTank SecondStageSeparation

Surge tank is maintained at a lower pressure to stabilize crude i.e. to removemaximumofassociatedgasfromthecrudeoil. OilfromsurgetankscanbeeitherpumpeddirectlywithMOLpumpsor canbedivertedtothirdstageseparators(Surgetank3). Separated crude oil is pumped with CTP / MOL pumps to export trunk lines. SeparatedGasisdivertedtoGascompressionmoduleafterboostingthe pressureLPboostercompressor. SeparatedWaterisdivertedtoProducedwaterconditioningUnit.

WELL PLATFORMS

FROM / TO BHS

Gas For Sales HP Flare LP Flare

ZA

IU

WB
FROM / TO BHS

HP Booster Compressors C-1470A C-1470B LP Flare HP Flare P=4 KSC E-1280 Crude oil Heater V-1300 Surge tank TR A LCV-1304B TO RESTART PUMP LP Flare LP Booster Compressors

A PB
From ICG IA R O D U IB C T I O N SG M SM A N SR ST From ICD I F O L D
Hot oil supply E-1160 WF Heater Skimmer Oil WF Heater Hot oil supply P=8 KSC E-1150 V-1210 Separator TR A

A
II stage C-1500A I stage II stage C-1500B I stage P U M P S U C P=2.25 KSC V-1380 Stabilization tank T I O N M A N I TO RESTART PUMP F O L D

Hot oil supply

A
O I L

ID

M
HP Condensate HP Flare P=8 KSC V-1220 Separator TR B

LP Flare HP Flare Hot oil supply P=4 KSC E-1290 Crude oil Heater LCV-1314B V-1310 Surge tank TR B

A N I F O L D

IC

IQ

IS

SD

SEPARATIONOF Oil Processing OIL/GAS/WATER

TO SUMP

To Produced Water Flesh Vessel

WASTEHEAT RECOVERY HotOilSystem

XSDV

Heat Exchanger E2810

T=400C
HIC 281 1

B Y P A S
T=250C

NITROGEN
BLANKETING

PCV

PSV
PCV

D U C T TIC 2814

Hotoil ExpansionTank catchpot

TGExhaust

F I L T E R

SupplyHdr.
PCV 2853

PIC

F I L T E R

ReturnHdr.
FCV 2850

TIC

FIC
TCV2881

P P

TrimCooler E2880

Crude Oil Export

TR A TR B
Pump Suction Manifold

TO ONSHORE TO HEERA

TR A RECYCLE

FROM/TO

LCV-1304

BHS

CTP-1320

CTP-1330

CTP-1340

MOL-1350

MOL-1360

MOL-1370

LCV-1384

T/M-1

T/M-2 LCV-1314

TR A
Discharge Manifold

TR B
TR B RECYCLE TO SURGE TANKS

CRUDEEVACUATIONBYSBMANDTANKER

GASCOMPRESSION,DEHYDRATION ANDEXPORT

GasCompression.

GasfromSeparators,SurgeTanksandexportgasesifanyfromotherprocess platformsarecompressedtoabout90100kg/cm2pressureasperthefield gasliftrequirement. Normally Gas turbine driven Centrifugal compressors (PGCs Process GasCompressors)areused.

Gases compressed in PGCs is dehydrated to prevent formation of GAS HYDRATES.Gashydratesareformedatlowtemperatureswhenmoistureis present in Hydrocarbon gases. These gas hydrates are ice like substance whichpreventthesmoothfloworblocktheflowofgasesingas flowlines.

GasHydratescanbeformedinAdjustableChokeValves,PCVs&GLVsinGI Lines where Throttling of gases give rise to low temperatures.(Joule Thomsoneffect).ThiscanaffectproductionphenomenallyfromGas liftwells.

GASCOLLECTIONANDCOMPRESSION
Dehydration Manifold

Inlet Manifold

Cooler

Cooler

Cooler

1st Stage K.O.D

2nd Stage K.O.D

3rd Stage K.O.D Discharge K.O.D

FuelGas

GG
M

P/T

LP

INT

HP

Cond Hdr

GasDehydration

Compressed Gas is dehydrated in a Glycol contactor with Tri Ethylene Glycol(TEG)asanabsorbentformoisturefromcompressedgas. Glycolcontactorisbubblecaptraycolumnwithmanybubblecaptrays.TEG flowscountercurrentwithcompressedgasfromthetopofthecolumn. TEG coming in contact with compressed gas in the bubble cap trays selectivelyabsorbsthemoisturefromthegasanddehydratesit. The dehydrated gas is sent to feed gas lift wells in priority basis and remainingtoexportgasline. The TEG rich in moisture is sent for reconcentration , converted to Lean glycolandrecycledbacktocontactorfordehydration.

Compressor OutletMnaifold

GasDehydration
LiftGas NetGas

LeanGlycol/ GasExchanger

Coalescer Separator Glycol Tank Contactor FlashDrum

Lean/RichGlycol Exchangers Glycol

Still

F
Glycol Scrubber

F F Reboiler

GlycolStorage

HotOil Supply CirculationPumps BoosterPumps

CondensateHdr ClosedDrainHdr

GASDEHYDRATION GASGLYCOLEXCHANGER

REGENERATIONOFGLYCOL

PRODUCED WATER TREATMENT

ProducedWaterConditioning
ThewaterproducedalongwithOilandGasfromthewellsistobetreatedtowithin acceptablelevelsofqualityintermsofoilppmbeforeitisdischargedintothesea. ProducedWaterConditioningunitnormallyconsistsofFlashVessel,CPISeparators, IGF(inducedGasfloatationUnit)andSumpcaisson.

FlashVessel ReceiveswaterfromBothInletSeparatorsandSurgetanks.Itismaintainedat0.8kg

pressure. In flash Vessel mostofthedissolvedgasesintheproducedwaterflashesout whichisroutedtoLPflare header.AssociatedOil fromtheproducedwaterintheflash vesselisroutedtocloseddrainheaderandiscollectedinthesumpcaisson.

CPIseparators
WaterfromtheflashvesselflowstomanyCPIseparators(corrugatedplateinterceptor)inparallel.OilfromCPI Separatoriscollectedinatankfromwhichitispumpedtooilmanifold.GasgoestoLPFlareheader.

IGFunit
Water from CPI Separator Flows to IGFunit. IGF is a tank in which gas bubbles are aerated with motor driven agitators.Thisbubblesfloattheoildropletstosurface.ThiscollectedoilispumpedtoCPIseparators.

SumpCaisson
Water from IGF is routed to Sump Caisson which is a vessel with bottom end open through which water continuouslydrainsintothesea.Oilfloatinginthesurfaceof thesumpcaissoniscollectedintheblowcaisson andliftedupandflownintotheskimmerwithgasinjection.

PFD PRODUCEDWATER CONDITIONING

ProducedWaterConditioning
LPFlare Produced Water

Flash Vessel IGF

CPISeparator

Sump Caisson Tank

SurgeTank

ClosedDrain

Skimmer
LPFlare FeedGas ClosedDrain

HotOil Supply

Skimmer
Blow Caisson

Sump Caisson

OpenDrain SurgeTank

WATERINJECTION

 WaterInjectionisdonetomaintainReservoirpressureaswellasWaterflooding. TopreventdamagetotheReservoirthequalityofwaterinjectedisstrictlycomplied with.Also,thehealthofthepipelinescarryingtheinjectionwatertothewellsandwell platformsistakencareofbydozingchemicalstopreventcorrosionandgenerationof H2SbySRBcolonies.

WaterInjection

TheMajorcomponentsofWaterInjectionsystemsare:
SEAWATERLIFTPUMPS COARSEFILTERS FINEFILTERS DEOXYGENATIONTOWERS BOOSTERSPUMPS MAININJECTIONPUMPS CHEMICALDOSINGSYSTEM
CHEMICALDOZINGSYSTEM
FLOCCULANT SCALEINHIBITOR CORROSIONINHIBITIOR CHLORINATION BACTERICIDE OXYGENSCAVENGER

SEAWATERTREATMENT FORWATERINJECTION

SEAWATERLIFTINGANDFILTERING

WaterfromseaisLiftedwithseawaterliftpumpsandfed to CoarseFiltersandfinefiltersforfiltering. Coarsefilterstheparticlesarefilteredto20microns Finefilterstheparticlesarefilteredupto2microns. Poly electrolyte and coagulants are added in sea water lift pump discharge to promote coagulation of suspended particles.

SEAWATERLIFTING FILTERATION
TOFFIC
FIC FIC FIC FIC FIC

FLOWRATE/FILTER:425.M3/HR INLETTEMP:21310C INLETPR:7KG/CM2

FINEFILTERS

F1170

F1180

F1190

F1200

F1210

F1220

FILTERSUPTO 2MICRONS

POLYELECTROLYTE

BEDLEVELDRAIN

BEDLEVELDRAIN

BEDLEVELDRAIN

BEDLEVELDRAIN

BACKWASHOUT

BACKWASHOUT

BACKWASHOUT

BACKWASHOUT

BACKWASHOUT

BACKWASHOUT

COAGULANT

BEDLEVELDRAIN

BEDLEVELDRAIN

BACKWASHIN

BACKWASHIN

BACKWASHIN

BACKWASHIN

BACKWASHIN

BACKWASHIN

BACKWASHRATE MIN::225M3/HR MAX:450M3/HR

FT

TOVACCUMPUMPS

DEFOAMER

TODEOXYGENATION TOUTILITYWATERHEADER

CHLORINATORS
FROMUTILITYWATERHEADER

F1110
CHPRODUCTION MIN:7.0KG/HR NORMAL:7.0KG/HR MAX:8.34KG/HR

F1120

F1130

CH1060

CH1070

FILTERSUPTO 20MICRONS

AIRFILTERS

COARSEFILTERS

OVER BOARD CAPACITY:1200M3/HR NO.OFSATGES:2 3/HR MIN.FLOW:218M

M
BLOWERS

M P1010 P1020 SEAWATERLIFTPUMPS P1030

DISCH.PR:7.1KG/CM2 MOTORPOWER:460KW SPEED:1500RPM

DEOXYGYNATIONANDPUMPING

The filtered water flows to Deoxygenating towers for removal of oxygen. Deoxygenationpreventsformationofaerobicbacterialcolonies(sulfur reducing bacteria) in the WI flow lines. Vacuum pumps and Oxygen scavengerchemicaldozedfacilitatesoxygenremovalinthetowers. Booster Pumps take suction from Deoxygenation Towers and feed MainInjectionPumps. Scale inhibitors, Bactericide and corrosion inhibitor chemicals are dozedinthedischargeofboosterpumps. MIPsdischargethetreatedwatertoWaterInjectionsubseapipelines towellsandwellplatformsforinjectingintowaterinjectionWells.

DEOXYGENATIONTOWERTRA
FIC

AIRFILTERS

DEOXYGYNATIONANDINJECTION

VACCUMPUMPS
EJECTOR M1320

CAPACITY:1129.5M3/HR NORMAL:982.25M3/HR

AIRRATING:28.2KG/HR P1350

CAPACITY:851M3/HR OXYGENCONTENTOF TREATEDWATER:0.02MG/LIT

OXYGENSCAVENGER FFIC

M
P1360

DEOXYGENTION SEPARATOR

M
LIC SEALWATER XSPL

OVERBOARD CORROSIONINHIBITOR

SCALEINHIBITORII

SCALEINHIBITORI

BACTERIOCIDEI

OVERBOARD

BACTERIOCIDEII

MAININJECTIONPUMPS
CAPACITY:415M3/HR MOTORPOWER:2250KW MINIMUMFLOW:103M3/HR SPEED:2985RPM P:134.7KG/CM2

PIC

DEOXYGENATIONTOWERTRB
FIC AIRFILTERS

CAPACITY:851M3/HR
EJECTOR M1420 P1450 DEOXYGENTION SEPARATOR

P1610

HCV

M
P1510

MOTORPOWER:322KW SPEED:1480RPM MINIMUMFLOW:212M3/HR P:10KG/CM2

PCV

BOOSTERPUMPS

M
SCALEINHIBITORI SCALEINHIBITORII

M
P1520

CORROSIONINHIBITOR

P1460

BACTERIOCIDEI

BACTERIOCIDEII

OXYGENSCAVENGER

P1630

M
VACCUMPUMPS
LIC SEALWATER

OVERBOARD P1640 PCV

HCV

M
P1530 OVERBOARD OVERBOARD P1650 XSPL

PIC

SE WI11 SP

L1680

P1620 OVERBOARD

L1660

FireDetection&SuppressionSystem
DetectionSystem GasDetection FusiblePlug FireDetection SmokeDetection HeatDetection Escape / Abandon
SuppressionSystem FIREWATERPUMPS WaterSprinkler DryChemical FM200 CO2 Extinguisher AFFFSYSTEM

Escape Ladder Scramble Net Life Ring Life Raft Life Boat Jumping Rope

91

UTILITIES

POWERGENEARTION GASTURBINEDRIVENGEBERATORS WATERMAKERS ROWATERMAKERS LIVING QUARTERS AND ASSOCIATED REQUIREMNETS LIKE LAUNDRY,GALLEY EMERGENCYDIESELGENERATORS COMMUNICATIONSYSTEMS

SEWAGETREATMENT

NEWTECHNOLOGIES
Intelligentwells DIGITALOILFIELD MULTIPHASEPUMPING SUBSEASEPARATIONANDREINJECTION GASTOWIRE

Intelligent Wells
Wells Equipped at Completion with Downhole Controls and Sensors
Horizontal producer

Proactive Remediation of Fluid Inflow

Remote controlled Downhole zonal control valves Implement reservoir decisions without intervention
Optical Pressure Gauge

Pilot well

Gas Injector

Continuous data from wells

Pressure Performance Downhole Seismic Inflow Distribution Reservoir Saturation Flowing Phase

Optical Distributed Temperature Gauge. Data is transmitted up the wellbore via fibre optics.

DIGITAL OILFIELD
Data Store

HIVE
Real-time Data Transmission Decision Driven Facilities Analysis model Business model Reservoir model Market Drivers & intelligence

Facilities 4D/4C - Permanent seismic

Integration for Decisions

Control, Optimisation & Intervention Export/Transport

Ahighresolubledataisobtainablebya4Cseismic surveyusing4componentsOBC(marineearthquake cable)withahydrophoneand3geophonecomponents.

Reservoir Management

Well Construction Intelligent Wells e-business

MULTI PHASE PUMPING

Multiphase production systems require the transportation of a mixture of oil, water and gas, often for many miles from the producing well to a distant processing facility. This represents a significant departure from conventional production operations in which fluids are separated before being pumped and compressed through separate pipelines. By eliminating this equipment, the cost of a multiphase pumping facility is about 70% that of a conventional facility and significantly more savings can be realized if the need for an offshore structure is eliminated altogether. However, multiphase pumps do operate less efficiently (30-50%, depending on Gas volume fraction and other factors) than conventional pumps (60- 70%) and compressors (70-90%). Still, a number of advantages in using multiphase pumps can be realized, including: 1)Increased production through lowering backpressure on wells; 2)Elimination of vapor recovery systems; 3)Reduced permitting needs; 4)Reduction in capital equipment costs; and, 5)Reduction in footprint of operations .

CONVENTIONAL AND MULTIPHASE PUMPING

Multiphase pumping is a relatively new technology and acceptance has been hampered by a lack of engineering design tools. Recently, pipeline simulation codes have incorporated the ability to model multiphase pump performance as part of the overall multiphase production system

SUBSEA PROCESSING
Normallyusedindeepwater Separationofheavyoilandwater Reinjectionofwatertoboostproductioninamaturefield development. Theseparationsystemmayalsoincludescyclonemodulesthatwill performwatertreatmentbeforereinjectionthewaterbackintothe reservoir.

"atruesubseadevelopmentisveryenvironmentallyfriendly."

THANKS