EP General Surface Engine Ring

8/3/2019 EP General Surface Engine Ring

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Surface Disciplines


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Surface Engineering Agenda next 1 days

Surface Discipline Overview

Surface Engineers and the ORP

Overview of Surface Systems

Meeting Product Specifications

- Oil and Water Processing

- Gas Processing

Process Safety (Self-Study)

EP Learning and Leadership Development


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Surface Discipline Overview

Facilities Engineering

Project

Execution

Discipline

Engineering

Production Engineering

Production

Operations

Maintenance

& Integrity

Production

Technology &Chemistry

Global

Logistics


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Facilities Engineering Discipline - Detail

ManagementCommunity

ServicesDLT

Eng./ConstructionDLT

P

rocessDLT

PipelinesDLT

Project Execution

ManagementCommunity

ServicesDLT


P

rocessDLT

MechanicalS

taticDLT

RotatingE

quipmentDLT

PipelinesDLT

Materials.

Corr

,Integ

DLT

ElectricalD

LT

Contro

l&AutoDLT

Of

fshoreDLT

CivilD

LT

S

ubsea

DLT

Discipline Engineering

Me

tocean

DLT

ManagementCommunity

ServicesDLT


P

rocessDLT

PipelinesDLT

Project Execution

ManagementCommunity

ServicesDLT


P

rocessDLT

MechanicalS

taticDLT

RotatingE

quipmentDLT

PipelinesDLT

Materials.

Corr

,Integ

DLT

ElectricalD

LT

Contro

l&AutoDLT

OffshoreStructuresDLT

Civil(

Onshore)DLT

S

ubsea

DLT

Discipline Engineering

Me

tocean

DLT


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Process Engineering

Process Engineers deal with the Big Picture (Systems)

They determine what must be done to meet productspecifications

They are where subsurface uncertainty collides withreality(for the first time)



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Mechanical, Pipeline and Corrosion Engineers

Static Equipment (eg vessel wall thickness, nozzlelocations, fabrication specifications, piping specs)

Rotating Equipment (eg compressor and pumpdefinition and specification)

Pipeline Engineers (eg hydraulics and constructionrequirements)

Materials and Corrosion (define materials of

construction, determine corrosion risk mitigation)



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Electrical and Control & Automation

Engineers

Electrical (electrical distribution definition, sizing electricalcomponents, generators, etc.)

Control & Automation (Specify controllers, DCS systems,

data & IT architecture, etc.) Instrument (determine end devices and elements needed

for control and measurement



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Civil, Offshore, Metocean and Subsea

Civil (specify land preparation, concrete storage,buildings, roads, piping and foundation)

Offshore (define offshore structures)

Metocean (specify wave and sea loads for offshorestructures and arctic design)

Subsea (Define specialized subsea equipment,

umbilicals, etc. Integrates subsea architecture)



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Surface Engineering & the ORP


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Remember the Project Framework (ORP)?

A decision based approach to maturing new Business opportunitiesand developing projects

Framework reviewed by a Value Assurance Review (VAR) teamRecommend to Project Team and Decision Review Board (DRB)

Decisions endorsed by DRB to go forward to next Phase

All projects biased for Major Projects


VAR 1 VAR 2 VAR 3 VAR 4 VAR 5

IDENTIFY &IDENTIFY &

ASSESSASSESSSELECTSELECT DEFINEDEFINE EXECUTEEXECUTE OPERATEOPERATE


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Defining the Project Framework



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The Value Story



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Generic Deliverables



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Opportunities within Opportunities




ASSESSASSESS

SELECTSELECT DEFINEDEFINE EXECUTEEXECUTE OPERATEOPERATE



ASSESSASSESS SELECTSELECT DEFINEDEFINE EXECUTEEXECUTE OPERATEOPERATE



ASSESSASSESSSELECTSELECT DEFINEDEFINE EXECUTEEXECUTE OPERATEOPERATE


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Front End (Phases 1 & 2)

Have we considered a broad range of Options?

Have we selected the option which maximizes

value for the opportunity?

Have all elements in TECOP been addressed Are there solid mitigation planned in the Risk

Register?

Can we build it to reflect subsurface uncertainty?



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Meeting Requirements

- Dealing with UncertaintyWhere uncertainty collides with resource commitment


Potential production profiles (from RE sources)

0

20

40

60

80

100

120

140

160

0 2 4 6 8 10 12 14 16 18 20 22 24

Year

Low Case

Base Case

High Case


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Uncertainty Example


Water Depth

80 meters

150 meters


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Meeting Requirements

- Not the same on every projectWhat type of Project is this ?


0

200

400

600

800

1000

1200

1400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Production Year

MMSCFD


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Risk Management


Build for P50 (15 Phase 1 wells) - Realize P85

0

200

400

600

800

1000

1200

1400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Production Year

MMSCFD

Why Drill Extra Wells?


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Phases 3 & 4: Define & Execute


Process Flow Schemes

P&IDs

Equipment Data Sheets

Process Safeguarding

Flow Scheme(s)

Data Sheets,Drawings, Diagrams

Preliminary Plant Layout Final Plant Layout

Preliminary Project Planning Detailed Project Planning

Preliminary Cost EstimateDetailed and Final

Cost Estimate


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Phase 5: Operate

Support to Start-up.

System Performance identification and verification (Testing).

Identification of System Operating and Integrity Envelopes

Optimization of Process system

Debottlenecking



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Engineering Support to Operations

Design Phase

Incorporate operations requirements in design (life cycle costs) Operating manual input and Operator training assistance

Operating guidelines/envelopes (processing & safety)

Operations simulation model

Operations Phase Commissioning and acceptance tests

System modeling, calibration, optimisation

Monitoring process, utilities and environmental

Performance testing, Troubleshooting

What if calculations Debottlenecking

Develop bottleneck portfolio

Engineer plant changes (Hazops, safety)



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Operating Envelope - Separator


Demisting Constraint

Gas Outlet Nozzle

Constraint

Inlet Nozzle Constraint

Constraints: Degassing,

Liquid Retention time, and

Liquid Outlet Nozzle

Operating Envelope

G

a

s

F

l

o

w

Liquid Flow

Relief Valve Constraint


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Debottlenecking


GAS WELLS

OIL WELLS

HP GAS SEP

HP OIL SEP

IP SEP

FWKO

OIL TREATER

FLASH GAS COMPRESSOR

BOOSTER GAS COMPRESSOR

FILTER SEP

TEG CONTACTOR

EXPORT GAS

DRY OIL TANK & EXPORT

DRY OIL TANK VAPOURS

Individual pieces of equipment

to whole processing systems


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Why do it?

Development of new (small) reservoirs in vicinity Change in production fluid compositions

Reservoir fluids/rates not as predicted

Identification of spare capacity in existing plant

New opportunities based on new technologies

New plant is too expensive


0

5

10

15

200 18Project Cost (million US$)

CapacityIncrease(Millionm3/d)

New Module Debottlenecking


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What are the alternatives?

New Plant

Replace / Add Equipment

Modify Equipment

Change Operation (AdjustEnvelope)


Cost

Debottlenecking

New Build

Optimization


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Debottlenecking Projects


Normal Greenfield Project

1. Assess High Level2. Select Choose between realistic options3. Develop Start getting detailed4. Execute Detailed Engineering, construction etc.5. Operate

Debottlenecking Project1. Assess Perform operational tests2. Select will already have to get into details to prove realistic

options3. Develop May well be a short process (as you already have

the detail).4. Execute - CAPEX .. but also what about cost of shut-down?5. Operate

Exercise


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Discipline Involvement in ORP

A. A major new field has been found and is currently undergoing initialappraisal. Youre assigned to the team as the Process Engineer.

B. Its just been discovered that the wells in an recent onshore oil projectare much more prolific than originally estimated. Youve been told toinvestigate Debottlenecking.

C. A major LNG expansion has just been announced. This includes thebuilding of a large 38-42 100+km pipeline to supply the LNG plant withgas from a number of different gas & gas/condensate fields. Youre on

the pipeline team.D. The development of a small offshore gas field near existing

infrastructure has been under study for some time. Youre tasked withdistinguishing technical pros and cons of each of the remaining options:

A subsea satellite tieback to the nearest existing platform.

A stand-alone Jacket development.



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Exercise ScopeIn your syndicates:

Decide which stage in the ORP you are in and explain why

List what you think are the key Surface Eng disciplines in your

example. Who would likely be the lead? What Disciplines are

in the Core team, and which are supporting? What level of

detail do you think is appropriate?

Summarise on one or two flip charts

On return nominate someone to present to the class, and be

prepared for a 5-10 minute discussion.



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High Level Summary of Surface Facilities

Oil Field Facilities A Simple O er ie


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Oil Field Facilities - A Simple Overview


Gathering Station

Class Discussion(10 mins)

Export Terminal

Production Station

Wellhead Well Cluster

Pipeline


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Well Sites


To accommodate drilling operations

To provide for maintenance / workovers To provide containment in case of accidents

Possible facilities :

Wellhead(s) / Flowline(s)

Production Manifold

Production Testing

Gaslift / Gas Injection / Water Injection

Wells

To G.Stn

Production

Wellhead

Cellar for

small spills

..... Single Wellhead

..... Cluster of Wellheads


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Gathering Station


Gathering Point for well fluids from various well sites

Primary separation of gas and oil (and possibly water)

Possible Facilities :

Inlet / Production Manifold

Oil/Gas Separators

Production Testing

Surge Tanks

Pumps

Gaslift, Gas/Water Injection Manifold

..... Combined Processing Station

..... Cluster of Gathering Stations

Tank PumpInlet

Manifold

& Separators

Well

Fluids

Gas

Liquid


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Production Station


Treatment Point for produced fluids Separation of gas, oil and water/solids

Degassing, Dehydration, Deoiling

Product Evacuation

Waste Disposal

Facilities / Utilities Control

Logistic / Manning BaseWater Oil Gas

Deoiling Conditioning

Treatment

Compression

Degassing

Dehydration

Disposal

Injection

Evacuation Evacuation

Utilities

Disposal

Injection


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Separation


Bubblepoint Liquid

Dewpoint Gas

Centrifugal Pumps


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Centrifugal Pumps


Centrifugal Compressors


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Centrifugal Compressors



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Export Terminal


Final Processing / Treatment Capacity to consider offtake rate & schedule

Oil spillage / fire fighting considerations

Controlled drainage system

..... Fixed roof tanks

..... Floating roof tanks

Tank

Foundation Bund WallDrain

Documents

EP General Surface Engine Ring