Surface Facilities Rev 3

Production Engineering Mary Gonzalez
Surface Facilities
1
Process System Classification
Crude Stabilization
Gas Processing
Incoming Produced water

Effluent
handling
Solid handling
Power Generation
Offsite facilities
2004 NExT All Rights Reserved

Production system flowchart

Schematic of Total Production System
Gas Disposal
Flare
Gas Sales
Gas Processing Gas Lift
Module Gas Re-injection
Gas
Oil
Crude Oil Crude Oil
Reservoir Field Storage Oil Sales
Separation Treating
Water Disposal
Water Produced Water
Treating or Re-injection

On Shore and Offshore Production facilities 4

Production Equipment
8
Production Equipment
1) Crude Oil Stabilization Systems

Overview of Wellhead Systems
Inlet Manifold
Pig Launchers / Pig Receivers
Separators
Dehydrators / Desalters
Heat Exchangers
Transfer Pumps
Metering Systems

Production Equipment - (Contd)
2) Water Treatment Systems

Water Injection Package
Hydrocyclones
Prod. Water Degasser
Oil in Water Monitors
10

3) Gas Treatment Systems

TEG Dehydration Unit
Gas Compressor Package
11

4) Flare Systems
Flare
Flare Ignition Panel
Flare Knock Out Drums
12

5) Instrumentation
Valves (Control Valves, PSV, Manual Valves)
Level Measurement & Control
Pressure Measurement & Control
Temperature Measurement & Control
Flow Instruments
Electronic Control Systems
MCC / Control Cabin
13

CRUDE OIL STABILIZATION SYSTEMS

OVERVIEW OF AN OIL FLOW SYSTEM
14

WELLHEAD SYSTEMS
CHRISTMAS TREE
When the well has been drilled and

completed, a Christmas tree is
installed to control the flow of oil and
gas. The Christmas tree is permanent
piece of equipment (an assembly of
control valves, pressure gauges, and
chokes) at the top of the well.
15

CHOKE MANIFOLD / INLET MANIFOLD
INLET MANIFOLD
The Inlet Manifold

receives fluids from
different wells and
combines the flow on a
single header for further
processing.
16

PIG LAUNCHERS / RECEIVERS
Pigging in the maintenance of pipelines refers to the practice of using pipeline inspection
gauges or 'pigs' to perform various operations on a pipeline without stopping the flow of
the product in the pipeline. These operations include but are not limited to cleaning and
inspection of the pipeline. This is accomplished by inserting the pig into a 'pig launcher'
- a funnel shaped Y section in the pipeline. The launcher is then closed and the pressure
of the product in the pipeline is used to push it along down the pipe until it reaches the
receiving trap - the 'pig catcher'.
http://www.youtube.com/watch?v=KMoCbqOT7yU
17

SEPARATORS
The separator is a
versatile piece of
equipment that allows
separation, metering, and
sampling of well effluent
components.
Features:
Mechanical components inside the
vessel improve the gravity separation
process and reduce retention time.
An adjustable oil-gas interface level
controller
A pressure controller to adjust the
separation pressure and improve
separation efficiency.
The vessel is protected against
overpressure by safety relief valves.
18

DEHYDRATORS / DESALTERS
A system, which controls the content of an impurity in a crude oil stream, includes an injector which
injects a demulsifier into a stream of produced wet crude oil in response to a control signal. A three-
phase separator receives the produced crude oil with demulsifier and partially separates produced water and
gas from the crude oil to provide a separated wet crude oil stream.
A dehydrator removes substantial amount of water from the crude oil/wash water stream to provide a
dehydrated crude oil stream. A monitor monitors the content of a predetermined type of impurity in the dry
crude oil stream and provides a corresponding impurity content signal to control apparatus. The control
apparatus provides the first and second control signals in accordance with the signal from the monitor so
as to control the impurity's content of the dry crude oil stream.
19

HEAT EXCHANGERS
PLATE TYPE HEAT EXCHANGERS

The plate heat exchanger, often called the plate-and-frame heat
Exchanger, consists of a frame which holds heat transfer plates.
A plate pack of corrugated metal plates with portholes for the
media is aligned in a frame and compressed by tightening bolts.
The plates form a series of channels for the two media.
The channels are sealed by gaskets which direct the fluid into
alternate channels. The fluids normally flow in countercurrent
flow, one in the odd number channels and one in the evenly
numbered channels.
20

HEAT EXCHANGERS
SHELL AND TUBE TYPE HEAT EXCHANGERS

A shell and tube heat exchanger is a class of heat
exchanger designs.It is the most common type of heat
exchanger in oil refineries and other large chemical
processes, and is suited for higher-pressure
applications. As its name implies, this type of heat
exchanger consists of a shell (a large pressure
vessel) with a bundle of tubes inside it.
Two fluids, of different starting temperatures, flow through the heat exchanger. One flows through the tubes (the tube
side) and the other flows outside the tubes but inside the shell (the shell side). Heat is transferred from one fluid
to the other through the tube walls, either from tube side to shell side or vice versa. The fluids can be either
liquids or gases on either the shell or the tube side. In order to transfer heat efficiently, a large heat transfer
21
area should be used, leading to the use of many tubes.
HEAT EXCHANGERS
INDIRECT FIRED HEAT EXCHANGERS

Skid-mounted indirect-fired diesel heater used
to raise the temperature of well effluents to
prevent hydrate formation, reduce viscosity, and
break down emulsions.
22

PUMPS
In Production Operations, a
transfer pump is usually part
of the surface equipment. It is
used to transfer fluids such as
oil, chemicals, or water from
one location to another.
Centrifugal Pump
Vertical In-Line Pump

Reciprocating Pump 23

METERING SYSTEMS
METER PROVERS
24

METERING SYSTEMS
GAS METERING SKID
25

WATER TREATMENT SYSTEMS

OVERVIEW
The injection of waters, both aquifer and seawater, is

extensively used to support and maintain the production
of oil and gas.
The main physical treatments of injection water are:
Filtration
De-oxygenation
Filtration is performed to remove particulates, macro-
invertebrates and organic matter down to less than 5
microns in size. De-oxygenation of the water is required
to reduce corrosion and aerobic bacterial growth.
26

WATER INJECTION PACKAGE
BASIC PROCESS SCHEME 27

HYDROCYCLONES
The hydrocyclone unit is

positioned downstream of the
water outlets on the separator
and upstream of the degasser.
Its function is to remove any
entrained oil from the water and
return it to the separation
process prior to the water being
sent to the degasser.
The hydrocyclone unit is a key

piece of equipment in the
treatment of produced water
prior to dumping it into a river or
sea or even reinjection back into
the reservoir. It is ideal for use
offshore due to its low size,
weight, retention time and
efficiency.
29

PRODUCED WATER DEGASSER
The function of the

degasser is to allow
the separation of
any oil and gas still
in the produced
water after
hydrocyclone
treatment.
30

OIL IN WATER MONITORS
Continuous on-line monitoring provides

the most responsive feedback loop for
measuring hydrocarbons in water.
Compared to laboratory grab sample
analysis, on-line monitoring provides cost
effective, continuous, remote, operator
unattended measurement of aromatic
hydrocarbons in water.
31

TEG DEHYDRATION UNIT
The basic function of the triethylene glycol (TEG) dehydration unit is to remove water vapor from natural gas
streams to an outlet water content meeting pipeline specifications. Dehydration, or water vapor removal, is
accomplished by depressing the water dew point (defined as the temperature at which vapor begins to condense into a
liquid) from the inlet dew point temperature to the dew point temperature for the outlet water content required.
Triethylene glycol (TEG)

and ethylene glycol (EG)
are the two most
commonly used glycols in
natural gas dehydration.
Dehydration with TEG is
typically used in field
production and gathering
units and at transmission
and storage facilities. TEG
dehydrators usually
operate with a tray or
packed column in which
the glycol counter currently
contacts the wet gas.
32

FLARE SYSTEMS
Plant relief systems.
HORIZONTAL FLARE
COANDA TIP
VERTICAL FLARE
33

INSTRUMENTATION
34

ELECTRONIC CONTROL SYSTEMS
DCS (DIST. CONTROL SYSTEMS)
35

ELECTRONIC CONTROL SYSTEMS
PLC (PROGRAMMABLE LOGIC CONROLLERS)
36

NEW TECHNOLOGIES
MULTIPHASE METERING
Multi Phase Meters

utilizes cross-
correlation of
capacitance signals to
measure individual
component flow rates,
while the fractions of
oil, gas and water are
determined by
combining
capacitance,
inductance and
gamma densitometer
signals. A venturi is
employed to extend
the operating range
into single-phase gas 38
or liquid flows. 2004 NExT All Rights Reserved
NEW TECHNOLOGIES
SUBSEA MULTIPHASE PUMPS
Operators of oil and gas

fields are constantly on
the look-out for more
cost effective production
processes and
more efficient methods
of draining hydrocarbon
reservoirs. Multiphase
pumps can efficiently
contribute to this, both in
deepwater and satellite
applications.
multiphase pumps enable boosting of the oil/gas/water mixture
from producing wells, without separating the gas from the
liquids. They are successfully deployed in remote or subsea
location, thus making wells and fields economically viable.
39

Uses:
Improve oil recovery, remove formation damage, clean blocked perforations or formation
layers, reduce or inhibit corrosion, upgrade crude oil, or address crude oil flow-assurance
issues. Injection can be administered continuously, in batches, in injection wells, or at times in
production wells.
CHEMICAL INJECTION PACKAGE 41

A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume.
Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through
a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively
incompressible, so the main action of a pump is to pressurize and transport liquids.
ARIEL COMPRESSOR PACKAGE 43

A partial list of centrifugal compressor applications include:

* In pipeline transport of natural gas to move the gas from the production site to the consumer.
* In oil refineries, natural gas processing plants, petrochemical and chemical plants.
* In air separation plants to manufacture purified end product gases.
* In refrigeration and air conditioner equipment refrigerant cycles: see Vapor-compression refrigeration.
* In industry and manufacturing to supply compressed air for all types of pneumatic tools.
* In gas turbines and auxiliary power units.
* In pressurized aircraft to provide atmospheric pressure at high altitudes.
* In automotive engine and diesel engine turbochargers and superchargers.
* In oil field re-injection of high pressure natural gas to improve oil recovery.
Compressor Module in-Singapore 44

Separator Unit (Indonesia)

46

47

Flare Tower
Back to chapter # 1
Slide 69
48

Surface Facilities Rev 3

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Surface Facilities Rev 3

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Production Engineering Mary Gonzalez

Incoming Produced water

2004 NExT All Rights Reserved

Production system flowchart

2004 NExT All Rights Reserved

On Shore and Offshore Production facilities 4

2004 NExT All Rights Reserved

1) Crude Oil Stabilization Systems

2004 NExT All Rights Reserved

Production Equipment - (Contd)

2) Water Treatment Systems

Prod. Water Degasser

Oil in Water Monitors

2004 NExT All Rights Reserved

Production Equipment - (Contd)

3) Gas Treatment Systems

Gas Compressor Package

2004 NExT All Rights Reserved

Production Equipment - (Contd)

Flare Ignition Panel

Flare Knock Out Drums

2004 NExT All Rights Reserved

Production Equipment - (Contd)

Level Measurement & Control

Pressure Measurement & Control

Temperature Measurement & Control

Electronic Control Systems

MCC / Control Cabin

2004 NExT All Rights Reserved

CRUDE OIL STABILIZATION SYSTEMS

2004 NExT All Rights Reserved

When the well has been drilled and

2004 NExT All Rights Reserved

CHOKE MANIFOLD / INLET MANIFOLD

The Inlet Manifold

2004 NExT All Rights Reserved

2004 NExT All Rights Reserved

2004 NExT All Rights Reserved

2004 NExT All Rights Reserved

PLATE TYPE HEAT EXCHANGERS

2004 NExT All Rights Reserved

SHELL AND TUBE TYPE HEAT EXCHANGERS

INDIRECT FIRED HEAT EXCHANGERS

2004 NExT All Rights Reserved

Vertical In-Line Pump

2004 NExT All Rights Reserved

2004 NExT All Rights Reserved

GAS METERING SKID

2004 NExT All Rights Reserved

WATER TREATMENT SYSTEMS

The injection of waters, both aquifer and seawater, is

2004 NExT All Rights Reserved

BASIC PROCESS SCHEME 27

2004 NExT All Rights Reserved

The hydrocyclone unit is

The hydrocyclone unit is a key

2004 NExT All Rights Reserved

The function of the

2004 NExT All Rights Reserved

Continuous on-line monitoring provides

2004 NExT All Rights Reserved

Triethylene glycol (TEG)

2004 NExT All Rights Reserved

Plant relief systems.