2. field development concept

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


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.


a. Onshore platforms

i. Cable tool drilling ii. Rotary drilling

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Lubbock, Texas


a. Onshore platforms

i) Pumpjack (nodding donkey) ii) Rotating

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a. Fixed offshore platforms

i) A Steel platform ii) A TLP

iii) A concrete gravity


a. Fixed platforms (deepwater)


a. Fixed platforms (deepwater)

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Spar

TLPSemi-

FPSFPSO (Wet)

Dry & Wet Trees Wet Trees Only

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a. Fixed platforms (deepwater)TLP

FPSO with Subsea Wells

Tanker

SubseaWells

FPSO

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a. Challenges for deepwater fields.

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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

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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

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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.

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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.

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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.

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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.

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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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The offshore installation process

The offshore maintenance

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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.

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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.

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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

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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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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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d. Power generation

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d. Power generation

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d. Power generation

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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.

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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.

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e. Accommodation/Living quarters

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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.

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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.

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a. FPSO

(Floating processing, storage and

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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.

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3. Mooring Systems

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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.

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a. Wellheads & protection Jackets

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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

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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.

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5. Integrated Development & Production

System

The integrated components may be added-on later to

meet the field development requirements

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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

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facilities

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facilities

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facilities

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facilities

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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

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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??

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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

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7. Q & A

2. field development concept

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