Petroleum Production Engineering (PR) K15PG-28

SURFACE PRODUCTION FACILITIES

Introduction

The oil and gas industry are usually divided into three major sectors: upstream, midstream and downstream.

The upstream sector:

Includes the searching for potential underground crude oil and natural gas fields, drilling of exploratory
wells, and subsequently drilling and operating the wells that recover and bring the crude oil and/or raw
natural gas to the surface.

The midstream sector:

Involves the transportation (by pipeline, rail, barge, oil tanker or truck), storage, and wholesale marketing
of crude or refined petroleum products.

Pipelines and other transport systems can be used to move crude oil from production sites to refineries and
deliver the various refined products to downstream distributors.

The downstream sector:

Commonly refers to the refining of petroleum crude oil and the processing and purifying of raw natural gas
as well as the marketing and distribution of products derived from crude oil and natural gas.

The downstream sector touches consumers through products such as gasoline or petrol, kerosene, jet fuel,
diesel oil, heating oil, fuel oils, lubricants, waxes, asphalt, natural gas, and liquefied petroleum gas

Well Head
The wellhead consists of the pieces of equipment mounted at the opening of the well to manage the
extraction of hydrocarbons from the underground formation. It prevents leaking of oil or natural gas out of
the well, and also prevents blowouts caused by high pressure. Formations that are under high pressure
typically require wellheads that can withstand a great deal of upward pressure from the escaping gases and
liquids. These wellheads must be able to withstand pressures of up to 20,000 pounds per square inch (psi).
The wellhead consists of three components:

A-The casing head

(Including casing hangers & Casing head spool)
B-The tubing head
(Including Tubing hangers & Tubing head spool)
C-The 'Christmas tree.’

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Casing Head

A casing head is a simple metal flange welded or screwed onto the top of the conductor pipe. The casing
head also serves to support the entire length of casing that is run all the way down the well. This piece of
equipment typically contains a gripping mechanism that ensures a tight seal between the head and the
casing itself. Casing Head Spool: used in flanged wellhead assemblies to secure the upper end of a casing
string and to suspend and seal the casing. Casing Hangers: is that portion of a well head assembly which
provides support for the casing string when it is lowered into the wellbore. When the casing string has
been run into the wellbore it is hung off, or suspended, by a casing hanger, which rests on a landing
shoulder inside the casing spool. Casing hangers must be designed to take the full weight of the casing
and provide a seal between the casing hanger and the spool.

CSG head spool

CSG hanger

TUBING HEAD

A spool-type unit or housing attached to the top flange on the uppermost oil-well-casing head to support
the tubing string and to seal the annulus between the tubing string and the production casing string. Tubing
head is a wellhead component that supports the tubing hanger and provides a means of attaching the
Christmas tree to the wellhead. Tubing Head Spool: Piece of equipment attached to the uppermost casing
head or smallest casing string which serves to suspend the tubing and to seal the annular space between the
tubing and casing. Tubing hanger: is a device attached to the topmost tubing joint in the wellhead to support
the tubing string. The tubing hanger typically is located in the tubing head, with both components
incorporating a sealing system to ensure that the tubing conduit and annulus are hydraulically isolated.

TBG head spool TBG hanger

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Safety Control Sub-Surface

Safety Valve
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
➢A Safety Control Sub-Surface Safety Valve (SCSSV) is a down hole safety device installed
in a well which can be closed in emergency.

➢The reason for using an SSSV is to provide protection to site and off-site personnel,
surface facilities the environment and the reservoir.

➢These valves are commonly uni-directional flapper valves which open downwards such
that the flow of wellbore fluids tries to push it shut, while pressure from the surface
pushes it open; This means that when closed, it will isolate the reservoir fluids from the
surface.

➢Most down hole safety valves are controlled hydraulically from the surface, meaning
they are opened using a hydraulic connection linked directly to a well control panel.

➢When hydraulic pressure is applied down a control line, the hydraulic pressure forces a
sleeve within the valve to slide downwards; This movement compresses a large spring and
pushes the flapper downwards to open the valve.

C-Christ-mass Tree:

A Christmas tree (X-mas tree) is an assembly of valves and fittings which forms the top of the completion.
It is connected to the tubing hanger spool and directs the flow of fluids from the production tubing into the
production flow line. It also provides vertical access to the production tubing for well servicing and side
access to the production tubing for pumping services, i.e. well kill, circulation and chemical injection
facility. The type of the X-tree may vary according to the reservoir pressure ( We have 5K, 10K, & 15K).

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Types Of Valve Fitting

Hook-up & Flow Line

Is a pipe conform the dimensional requirements of ASME (American Society Of Mechanical Engineers)
and used for conveying Liquid, Gas or anything that flows. The selection of a flow line depends on the
Flowing and the shut-in pressure-temperature, and the flow rate. The size of the flow line may vary from
1 inches to 24 inches with various Schedules (ex. 40, 80, 160) including Valves and Flanges with various
classes (ex. 150, 300, 600, 900, 1500, 2500)

Flow Line Fitting

Flow Line fitting main objectives:-

1.Produce change in geometry

2.Modify flow direction

3.Bring pipes together

4.Alter pipe diameter

The most common types of Flow line Fitting are as follow:

1.Elbow: It is a pipe fitting installed between two lengths of pipe or tube allowing a change of
direction, usually 90°or 45°.

2.Tee-Connection: is used to either combine or split a fluid flow. Most common are tees with the same
inlet and outlet sizes

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3.Reducer: is used to Change the piping diameter.

4.Gasket: is soft material used to be inserted between two flanges.

5.Expansion Joints: are used in piping system to absorb thermal expansion.

Types of flanges
Loose flange:-Are classified as

1.Thread flange: Threaded Flanges are used for special circumstances with their main advantage
being that they can be attached to the pipe without welding.

2.Slip on flange: Slip-On Flanges are probably the most common type of flanges in the industry
and ideal for lower pressure applications.

3.Blind Flanges: This flange is used to seal the end of pipes systems and prevent flow, making it
easy to conduct pressure tests.

Flow line valves

The types of most common used Flow line Valves are as follow:

1.Ball Valve: is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball to
control flow through it. It is open when the ball's hole is in line with the flow and closed when it
is pivoted 90-degrees by the valve handle.

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2.Gate Valve: is a valve that opens by lifting a round or rectangular gate out of the path of the
fluid; Gate valves are primarily used to permit or prevent the flow of liquids, but typical gate
valves shouldn't be used for regulating flow.

Globe Valve: is a type of valve used for regulating flow in a pipeline, consisting of a movable
disk-type element and a stationary ring seat in a generally spherical body.

4.Butterfly Valve: is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows for
quick shut off. Butterfly valves are generally favored because they are lower in cost to other
valve designs as well as being lighter in weight

Check Valve: non-return valve or one-way valve is a valve that normally allows fluid (liquid or
gas) to flow through it in only one direction.

6.Choke Valve: is a type of control valves, mostly used in oil and gas production wells to
control the flow of well fluids being produced; the main advantage of choke valves is that they
can be designed to be totally linear in their flow rate