POINT - Oil Production & Process Layout

7/21/2019 POINT - Oil Production & Process Layout

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Oil Production and Process Layout

1





Introduction

The production stage is the most important stage of awell s life! when the oil and gas are produced"

#$ this time! the oil rigs used to drill and complete thewell ha%e mo%ed off the well&ore! and the top isusuall$ outfitted with a collection of %al%es called aChristmas tree or 'roduction tree"

These %al%es regulate pressures! control flows! andallow access to the well&ore in case further completion

wor( is needed"From the outlet %al%e of the production tree! the flowcan &e connected to a distri&ution networ( of pipelinesand tan(s to suppl$ the product to refineries! natural

gas compressor stations! or oil e)port terminals" 3



Introduction

As long as the pressure in the reser%oir remains highenough! the production tree is all that is re*uired toproduce the well"

If the pressure depletes and it is consideredeconomicall$ %ia&le! an artificial lift method can &eemplo$ed"

4



Introduction

5



IntroductionTypical Crude Oil Production Train

6



Flowing Wells

Defined as any well whichhas sufficient pressure in thereservoir to cause the oil orgas to flow naturally to thesurface through thewellbore.

A well which produces oil orgas without any means ofartificial lift.

They require relatively little

equipment or expense tobring the oil to the surface.

The equipment commonlyused consists of tubingwellhead and christmas tree.

7



Artificial Lift

Artificial lift is a techni*ue used to &ring oil from thereser%oir to the surface &ecause of decreasing reser%oirpressure"

+enerall$ this is achie%ed &$ the use of a mechanical

de%ice inside the well ,(nown as pump or %elocit$ string-or &$ decreasing the weight of the h$drostatic column &$in.ecting gas into the li*uid some distance down the well"

Artificial lift is needed in wells when there is insufficient

pressure in the reser%oir to lift the produced fluids to thesurface"

It also often used in naturall$ flowing wells ,which do nottechnicall$ need it- to increase the flow rate a&o%e whatwould flow naturall$"

8



Artificial Lift ,cont/d"-

There are currentl$ four common methods of artificiallift0

#eam pumping

Su&mersi&le pumping

+as lift

1$draulic pumping

9



Artificial Lift 2 #eam'umping

The pump is designed to beinserted inside the tubing ofa well and its main purposeis to gather fluids frombeneath it and lift them to the

surface.The most importantcomponents are! the barrelvalves "traveling and fixed#and the piston.The pump is connected tothe pumping unit at thesurface by a string of suc$errods.%uc$er rods are stro$ed upand down in the tubing

activating the pump at thebottom. 10



Artificial Lift 2 #eam'umping ,cont/d"-

At the surface! a largemechanical de%ice calledthe &eam pumping unit isattached"

11



Artificial Lift 2 #eam 'umping ,cont/d"-

1. Engine or otor2. !ear reducer3. Cran" ar#4. Counter $eig%t

5. Pit#an ar#6. &al"ing 'ea#7. (a#p)on po)t8. *or)e %ead9. +ridle10. Poli)%ed rod11. (tu,,ing 'o-12.(uc"er rod)13. Tu'ing

14. Ca)ing 12




Depending on the si3e of the pump! it generall$produces 4 to 56 litres of li*uid at each stro(e" Often thisis an emulsion of crude oil and water"'ump si3e is also determined &$ the depth and weightof the oil to remo%e! with deeper e)traction re*uiringmore power to mo%e the hea%ier lengths of suc(er rods"

Ad%antages of &eam pumping0

1igh s$stem efficienc$"

Economical to repair and ser%ice"Fle)i&ilit$ 2 ad.ust production through stro(e length andspeed"1igh sal%age %alue for surface unit and downholee*uipment"

13




Ad%antages of &eam pumping0Limited to relati%el$ low production %olumes! less than7!666 &arrels per da$"Limited to onshore application ,&ig surface unit re*uired-"

14



Artificial Lift 2 Su&mersi&le 'umping ,ES'-

Consists of an electric motorattached to a pump on theend of the tu&ing string"The electric motor turns acentrifugal pump whichforces oil from the &ottom ofthe well! up through theinside of the tu&ing! and outat the surface"

The electricit$ is suppliedthrough an electric ca&leattached to the side of thetu&ing and connected to theelectric motor"

15



Artificial Lift 2 Su&mersi&le 'umping ,ES'-

16



Artificial Lift 8 Elect" Su&mersi&le 'umping Ad%antages of ES'0

1igh %olume and depth capacit$"1igh efficienc$ o%er 7666 #'DLow maintenance"9inimal surface e*uipmentre*uirements"1igh resistance to corrosi%edownhole en%ironments":se in de%iated wells and %erticalwells with doglegs"

Disad%antage of ES'0'oor a&ilit$ to pump sand"

17



Artificial Lift 8 +as Lift

A series of de%ices called gaslift %al%es are inserted into thesides of the tu&ing"The gas is in.ected into the wellthrough the tu&ing2casingannulus and enters the tu&ingthrough the gas lift mandrelsand gas lift %al%es"The fluid in the tu&ing is made

lighter &$ the gas! and as aresult! the mi)ture is pushed tothe surface &$ reser%oirpressure"

18



Artificial Lift 8 +as Lift ,cont/d"-

19




A source of gas! and compressione*uipment is re*uired for gas lift"'roper installation and compati&ilit$ ofgas lift e*uipment! ,surface and in thewell&ore-! are essential to an$ gas lift

s$stem" Ad%antage of +as Lift0+as Lift is an artificial lift process thatclosel$ resem&les the natural flowprocess and &asicall$ operates as anenhancement or e)tension of thatprocess" The onl$ ma.or re*uirement isan a%aila&le and economical suppl$ ofpressuri3ed gas"

20




Disad%antages of +as Lift0Not feasi&le if no source ofgas present"1igh initial capital purchasecost9aintenance intensi%e"Difficult to operate"

21



+as Lift ,cont/d"- 8 #asic Components

22



Artificial Lift 8 1$draulic 'umping

1igh pressure oil! is pumped intothe well through the tu&ing string"

At the &ottom of the well! thepowered oil enters a mechanicalde%ice! causing it to reciprocate"This mechanical de%ice acti%atesa pump! which lifts the oil fromthe producing formation! togetherwith e)pended powered oil to thesurface"The s$stems consist of a surfacepower fluid s$stem! a primemo%er! a surface pump! and adownhole .et or pump"

23



Artificial Lift 8 1$draulic'umping

'ower fluid from surface actuates theengine! which in turn dri%es the pump!and power fluid returns to the surfacewith the produced oil"

Ad%antages of 1$draulic 'ump0No mo%ing parts"1igh %olume capa&ilit$"9ulti2well production from a singlepac(age"

Low pump maintenance"Disad%antages of 1$draulic 'ump01igh initial capital cost"Comple) to operate"

24



Oil Treating

+enerall$! what comes out of the well is a mi)ture of oil!water! gas! and e%en sand"Foreign material! such as water and sand must &eseparated from the oil and gas &efore the$ can &e sold"

This process is (nown as oil treating or oil deh$dration!in which water is remo%ed from the oil "

The amount of this foreign material is referred to as thebasic sediment and water ,#S;W- "

Normall$! the #S;W content must &e less than 7<&efore the oil will &e accepta&le for sale"#asic t$pes of e*uipment used for oil treating areseparator! free2water (noc(out and heater=treater"

25



Separator

A separator is a large pressure %essel designed toseparate production fluids into their constituentcomponents of oil! gas and water"The separator utili3es the force of gra%it$ to separate

oil2gas mi)tures ,due to different densities of thefluids-"The oil which is hea%ier than the gas falls to the &ottomof the %essel and is ta(en off through the fluid line "

The lighter gas rises to the top and is remo%ed forseparate sale "

26



Separator ,cont/d"-

9a.or components of a separator0

primar$ separation de%ice and=or section"secondar$ >gra%it$? settling ,separating- sectionmist e)tractor to remo%e small li*uid particles from the gas"+as outletLi*uid settling ,separating- section to remo%e gas"

L*uid outlet

27



Classification of Separators

Classification &$ Operating Configuration0&ori'ontal separator!

@ ma$ %ar$ in si3e from 76 or 7 in" , 462B64 mm- indiameter and 5 to 4 ft ,766627466 mm- seam2to2seam ,S2to2S- up to 74 to 7 ft ,5 6625 66 mm- in diameter and 6to 6 ft ,7 B662 7B66 mm- S2to2S"

@ manufactured with mono2tu&e and dual2tu&e shell(ertical separator!

@ %ar$ in si3e from 76 or 7 in" in diameter and 5 to 4 ft250/305 ## S2to2S up to 76 or 7 ft ,B6462B 6 mm- in

diameter and 74 to 4 ft ,5 662 66 mm- S2to2S"%pherical separator!

@ usuall$ a%aila&le in 5 or B6 in" up to to in" indiameter"

28



Classification &$ Function0Two phase separator 0

@ gas is separated from the li*uid with the gas and li*uid&eing discharged separatel$"

Three phase separator 0@ In three2phase separators! well fluid is separated into

gas! oil! and water with the three fluids &eingdischarged separatel$"

Classification of Separators ,cont/d"-

29



9ono2tu&e 1ori3ontal Separators ,cont/d"-

30



9ono2tu&e 1ori3ontal Separators

31



9ono2tu&e 1ori3ontal Separators ,cont/d"-Horizontal Typical 3-Phase Separator

32



Dual2tu&e 1ori3ontal Separator

33



Dual2tu&e 1ori3ontal Separator

34





Gertical Separators ,cont/d"-

36



Spherical Separator

37



Free Water Hnoc(out

:sed to separate oil! water and gas"These mi)tures flow into the %essel through an inlet %al%eand then are allowed to slow down in the large settlingcham&er"

An$ free water mi)ed with the oil settles to the &ottom! oil isremo%ed through a separate line and gas which rises to thetop is e)tracted through a third line"In principle! free2water (noc(out is almost identical toseparator "

The %essel is called a free2water (noc(out &ecause it isdesigned to eliminate onl$ free water! not water which has&een emulsified"

38



Free Water Hnoc(out ,cont/d"-

The oil and water outlets are controlled &$ le%el controlled%al%es! which pre%ent the %essel from draining completel$and (eep the gas trapped in the top of the %essel"Commonl$ used for low pressure wells and can &e used tohandle high %olumes of fluid"

39



Free Water Hnoc(out ,cont/d"-

40



1eater2Treater

Also called emulsion treater! used to separate oil andwater emulsions"Similar to free2water (noc(out &ut the treater has heatingcapa&ilit$ with the inclusion of fire tu&es"The com&ustion of the gas within the fire tu&es is used to

heat oil and water emulsion"

41



1eater2Treater ,cont/d"-

As the oil and water mi)ture grows hotter! the emulsion&rea(s and forms into clean oil and clean water"The water is remo%ed from the &ottom and sent to thewater disposal s$stem"

The clean oil is drawn off the center of the %essel andsent to the oil storage tan(s for sale" An$ natural gas in the oil2water emulsion e)its at the topof the heater2treater"

42



1eater2Treater ,cont/d"-

43



Com&inations

A t$pical com&ination of e*uipment is shown &elow0Oil! water and gas produced as a mi)ture sent into free2water(noc(out"The remaining oil and water emulsion lea%es the free2water(noc(out and is transferred to the heater2treater"

On an offshore platform! a high pressure separator often will&e used instead of the free2water (noc(out"

(ur,ace ,acilitie) ,or typical oil $ell

44



T$pical Oil Treating Facilit$

45



Oil Storage and Sales 2 Onshore

At a t$pical facilit$! sufficient storage is pro%ided toaccommodate oil from two to three da$s of production"Oil ma$ &e withdrawn from the tan( and sold &$truc(=tan(er or through pipeline to the refiner$"

Lease AutomaticCustod$ Transfermeasures the%olume of oil as itpasses into the

pipeline" It alsomeasures the#S;W content"

46



Oil Storage and Sales 2 Offshore

Offshore production platforms can sometimes &e e*uippedwith oil storage e*uipment if the platform is located in shallowwater"The clean oil can &e sold through a pipeline e)tending fromthe platform along the sea floor to the land"

47



Oil Storage and Sales 8 Offshore ,cont/d"-

In deep water operation! oil is shipped through a pipelinealong the sea floor to another storage platform in shallowwater"Sometimes! storage platform in not necessar$ and the oilis shipped directl$ into the sales line"

For remote oilfield! deepwater locations and small oilfield!where sea&ed pipelines are not cost effecti%e! the use ofF'SO is a good option"Oil is stored in the F'SO and will &e offloaded ontotan(er"

48




Floating, Production, Storage and Offloading (FPSO)

49




E a!ple" Tui P(O

50




Su#sea $ells

51



Saltwater DisposalTo pre%ent en%ironmental pollution! the water producedmust &e re2in.ected into the ground! often into the sameroc( from which it was drawn"The water is ta(en from the oil processing e*uipments andusuall$ sent to a storage tan( until a sufficient %olume has&een accumulated"

Often in offshore operation!the salt water from the wellscan &e disposed of into thesea itself"

1owe%er! the water must first&e sent through se%eralcleaning de%ices whichremo%e an$ traces of oil"

52



+as Treating

Natural gas consists of %arious components which arepresent in different concentration ,water and impurities-"easons for treating0

To meet sales specifications and customer s

re*uirement"To reco%er other materials such as CO and elementalsulfur from 1 S ,higher price if mar(eted separatel$-"

To facilitate transmission 2 pre%ent h$drate formation"

53



+as Sweetening 'rocess

+as Sweetening is the most common gas treating process" Also (nown as amine gas treating or acid gas removal "The process consists of two main units0 a&sor&er andregenerator"In the a&sor&er! amine solution a&sor&s 1 S and CO fromthe upflowing sour gas to produce a sweetened gas stream,i"e"! an 1 S2free gas- as as a product and an amine solutionrich in the a&sor&ed acid gases"The resultant JrichJ amine is then routed into the regenerator,a stripper with a re&oiler- to produce regenerated or JleanJamine that is rec$cled for reuse in the a&sor&er"

54



+as Sweetening 'rocess

The sweet gas normall$ goes on to additional processingsuch as deh$dration and h$drocar&on reco%er$"The acid gas containing most of the CO and sulfur compounds is either flared or sent to a Claus sulfur reco%er$unit"

C1/C4

2

* 2(CO2

CO( Car'onyl)ul,ideC( 2 Car'on i)ul,ide

( ercaptan)

(our !a)

($eet e)idue !a)

cid !a)* 2(CO2

CO(C( 2

(* 2O

C1/C4

2

* 2O

55





Sample Applica&le Standards American 'etroleumInstitute ,A'I-0

' +! '75E!'7 A! '4 !'464! '447!'4 ! '7776!

Spec" 4L! Spec" 5F!

Spec" A! Spec" D!Spec" 75D! Spec"7 D! Std" 476! Std"4B ! Std" 4 6! Std"

7 ! Std" 7 ! Std"

7 ! Std" 6! Std76! etc"

American Societ$ of

9echanicalEngineers ,AS9E-0

#7 "4! #B7"7!#B7"B! #B7"5!#B7" ! etc"

#oiler and 'ressureGessel CodeSections I 8 IG!Section GIII!Di%isions I and II!

etc"

International Stds"Organi3ation,ISO-0B7 B! 7657 !765 B! 77 46!

74 5 ! 7445 !7B B! 744 6!7B466! 7B !7 66! etc"

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)nd of Presentation

Than$ you.

'oint Engineering Ltd"

Documents

POINT - Oil Production & Process Layout