School of EngineeringCOURSEWORK SUBMISSION SHEET
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Due DateDate SubmittedFor official use only
13TH APRIL 2014
13th APRIL 2014LATE DATE
MATRIC No.: 1312484
SURNAME: ABBEY HART
FIRST NAME(S): TUMINI TAMONUA REGINALD
COURSE & STAGE
MSc OIL AND GAS INFORMATION TECHNOLOGY
MODULE NUMBER & TITLEENM 501: OIL AND GAS ENGINEERING
COURSE
ASSIGNMENT TITLEGENERAL FIELD DEVELOPMENT COURSE WORK
LECTURER ISSUING COURSEWORKMR MIKE ROBINSON
I confirm:(a)That the work undertaken for this assignment is
entirely my own and that I have not made use of any unauthorised
assistance.
(b)That the sources of all reference material have been properly
acknowledged.
[NB: For information on Academic Misconduct, refer to
http://www.rgu.ac.uk/academicaffairs/assessment/page.cfm?pge=7088]
ABBEY-HART 10TH APRIL
2014Signed..................................... Date
......................................................
Markers Comments
Marker
Grade
A REPORT ON THE FIELD DEVELOPMENT PLAN TAKEN FOR THE DEVELOPMENT
OF THE CASABLANCA FIELD
NAME.SIGNATUREDATE
PREPARED BYABBEY-HART TUMINI (1312484)ABBEY-HART13th APRIL
2014
REVIEWED BYMR MIKE ROBINSON
EXECUTIVE SUMMARY Casablanca oilfield is a virgin field, about
to start undergoing development, in order to commence production of
oil and gas for high return on investment values on money spent
during development. During exploration stage of this field, data
and facts about the oilfield were taken by geoscientist, and passed
on to engineers in order to help support and influence decisions
taken, and choose certified equipments fit for use during the field
development phase. The data details are shown below:
Field Location60 kilometres away from nearest land fall;
Field Water Depth300 feet deep;
Number of wells planned5 wells;
Rate Predicted for Production30,000 bbls oil quantity per
day;
Field life Duration expected10 years;
Depth of reservoir12,000 feet;
Initial Pressure6,000 psia
Pressure of oil bubble point3,500 psia
Quality of CrudeSour 40 Degrees API
From the data taken by geologist, seismic survey information
were acquired with the most important and a little bit disturbing
one being the presence of sour crude as the quality of crude to be
produced during development. Sour crude simply means that the crude
contains high amount of hydrogen sulphide and other sulphuric
compounds, which gives it a sour smell. Presence of this have
tendencies of causing problems and therefore treatment would have
to be undertaken on all produce (Oil, Gas, Water) to prevent future
problems with the government.
Also occurring flow assurance issues like Asphaltene
Precipitation, Wax formation etc. are expected during development
so prevention methods would be placed to prevent this from
occurring and causing obstruction of fluids flow from well heads to
their final point of export or sales point.
Lastly, a preferred option is recommended for the progress of
this project and all of this would be discussed as development
planning is carried out. TABLE OF CONTENTS3EXECUTIVE SUMMARY
5INTRODUCTION
51.1 Aims of this report
61.2 Objectives of this report
61.3 Assumptions taking during Development
7SECTION A:
72.0 Analysis for Field Development
82.1 Well Head:
82.2 Manifold
82.3 Separator:
92.4 Gas Scrubber:
92.5 Compressor:
92.6 Gas Conditioning Unit:
102.7 Meters:
102.8 Pumps:
112.9 Hydrocyclones:
112.10 Water De-gassing Drum:
122.11 Heater Treater:
122.12 Storage Tank:
122.13 SBM:
122.14 Shuttle Tankers:
13SECTION A Part 2:
133.0 Tie Back Development
133.1 Subsea Production Template:
133.2 Subsea Tree:
133.3 Underwater Manifold
133.4 Multi-Phase Meters:
143.5 Risers:
143.6 Flow Lines:
143.7 Umbilical Cables:
14SECTION B
144.0 Flow assurance issues faced by Casablanca and Morella
facility.
144.1 Hydrates Formation:
154.2 Corrosion:
154.3 Paraffin Waxes:
154.4 Asphaltene Precipitation:
164.5 Technical Advantages of Casablanca and Morella
Platform.
164.6 Technical Disadvantages of Casablanca and Morella
Platform.
174.7 Commercial Advantages of Casablanca and Morella
Platform.
174.8 Commercial Disadvantages of Casablanca and Morella
Platform.
18Section C:
185.1 Recommendation of Preferred option
INTRODUCTION As a field consultant, I am commencing the
development of a new oil field that I have been assigned to, create
a flow diagram for superiors to propose on structures to be
followed and carried out ensuring that equipments installed are fit
of use and operation working conditions. Also perform a tieback
operation to a pre-existing facility located nearby called Morella
with distance of approximately 10km choosing most appropriate means
with less production risk. 1.1 Aims of this report1) To prepare a
plan, for the successful development of the Casablanca oil
field.
2) To show Mr Mike Robinson, I do understand all concepts up to
an adequate level of all the information he has been passing in
class sections.3) To further students knowledge from that of the
course notes by means of web and publication searches.1.2
Objectives of this report1) To learn how to prepare a flow diagram
so as to help give some structure of development for Casablanca oil
field.2) To know the functions of how various Equipments utilised
in development stage work e.g. the roles played by a separator.3)
To know how water treatment is carried out before being discharged
into the environment.
4) To give recommendation, and discuss a preferred option with
reasons why it was selected from both development concepts.1.3
Assumptions taking during Development1) Minimal amount of sand
present, due to lack of high water cuts so sand cyclones are not
installed in development.
2) High viscosity crudes present so heater treater would be
needed in development.
3) Fluid coming in from the wellhead comes in at very high
pressure and therefore a three stage (multi) separator is needed to
step down fluid pressure.4) Morella platform is producing above,
45,000 stock tank barrel oil per day and this is going to take some
years to decline to 45,000 stock tank barrel oil.
5) Presence of acidic gases (Hydrogen sulphide and Carbon
dioxide) in crude, so gas sweetening is carried out.
6) No presence of Nitrogen in acidic gases so gas sweeting would
not be carried out on it using Cryogenic removal process.
7) Minimal and acceptable amount salt present when oil is been
separated so electrostatic de-salters are not installed.
8) Health and Safety requirement of oil in water before disposal
is 40ppm maximum, for the region where oilfield is located.SECTION
A:
2.0 Analysis for Field Development As the field development
consultant working for RG E&P, in charge of developing the
Casablanca oil field a flow diagram has been prepared shown in
Figure 1.0 below to help give structure on the processes and steps
that would be taken for successful development of this new oil
field.
Figure 1.0: A process flow schematic diagram describing the
process steps required for the development of Casablanca field.2.1
Well Head: During production, fluids from reservoir flow to the top
of the earth surface, and are being produced at the wellhead. The
wellhead helps provide a pressure containment interface for
production activities carried out. The quality and quantity of
reservoir fluids produced are dependent on three main factors,
which are composition of hydrocarbon present, characteristics of
the reservoir produced from and lastly the field development scheme
set in place. The earlier first two, aforementioned factors are
controlled by Mother Nature itself and the last mentioned are
manipulated within the constraints of technological and market
value. (Frank Jahn, et.al; pg 236, 2013).Chemical Injection is
provided at the wellhead to prevent issues occurring due to flow
assurance.2.2 Manifold: Productions gotten from wellheads are
connected through flow lines to a tubular steel structure called
manifold. This manifold acts as a focal point and gathering centre
for all flow lines attached to various wellheads, in which the
stream of fluids from each wellhead are commingled together and
fluid production now starts here for all wellheads. This process
saves time and unnecessary expenses of producing from each wellhead
independently. Injection of demulsifiers occurs here to prevent an
emulsion from occurring between the oil and water interphase. This
makes the oil soluble in water so there would just be a single flow
phase and not multiple flows because oil floats on water due to its
density difference. Fluids then flow from the manifold into a
separator, passing through a choke valve installed on the flow
line, which causes the first pressure drop of fluid during
production.2.3 Separator: Normally referred to as the heart of
processing facilities during production. It separates the fluids
into phases gas, oil, and water, and help to support accurate
metering of it during production. When fluid flows from the
manifold through the choke valve into the separator system, it
comes in at a high-pressure rate and then a pressure drop occurs as
it goes through each of the various phases of separation installed.
As fluids enter the separator, it hits an inlet diverter, which
causes a change in flow direction and velocity of the fluid.
Initial gross separation in the separator, occurs at this point
first with water going to bottom, oil in the middle and gas at the
top. In the separator, gravity forces cause the heavier liquid
droplets to fall out of the gas stream to the bottom where the
liquid is collected. The liquid phase holds the liquid until an
appropriate residence time required to allow the entrained gas
break out of the oil and rise to the gas phase, and they do so
under buoyancy forces. In addition, how easy the gases breaks out
of the liquid is determined by the viscosity of the liquid present,
as liquid with high viscosities imply longer residence times.2.4
Gas Scrubber: As the gas, flows out of the separator it passes a
mist extractor, which acts as a barrier and causes small drops of
liquid that were difficult to be separated by gravity to fall back
into the liquid phase. The gas then flows into a gas scrubber,
whose function is to restrict and trap condensed liquids (i.e.
water and hydrocarbons) from the gases as it leaves the separators.
This function of the gas scrubber helps prevent liquids from
getting into the suction of the compressor thereby disrupting
functionality and causing erode on compressor rotating blades.2.5
Compressor: As gas moves through the processing stages, a drop in
pressure accompanies it and energy would need to be imparted into
it to cause an increase in pressure, before it can be transported
to the next processing stage. In this scenario, three separators
are used in stepping down the pressure, so the gas pressure
escaping the first separator is not same with the gas pressure
escaping the second and the third separator, so in such a
compressor is used to increase the gas pressure of the second and
third separator to be in range with the first separator.2.6 Gas
Conditioning Unit: Before the gas is made use of as fuel or flared,
it goes through the condition unit, which ensures water vapour is
absent in gases, as this can lead to hydrate formation and cause
corrosion in the presence of carbon dioxide and hydrogen sulphide.
It also ensures that contaminants like carbon dioxide and hydrogen
sulphide are removed, as hydrogen sulphide is toxic.To prevent such
hindrances, two processes are undertaken which are:
i. Gas Dehydration: This simply means removal of water vapour
present in gases.ii. Gas Sweetening: This means the removal of
hydrogen sulphide and carbon dioxide (acid gases) that are
present.
These two processes are performed together using absorption
technique in a contact tower or absorber. Chemical solvents such as
Monoethanolamine and Tri-ethylene glycol are combined together in
the contact tower, then the gases are bubbled as heat is being
applied slightly above atmospheric pressure. In the contact tower,
the glycol reduces the water contents sufficient to prevent water
dropout from the gases, and allows for efficient removal of the
hydrogen sulphide and carbon dioxide by the Monoethanolamine in the
gases. This help remove possibilities of hydrate formation, which
causes corrosion and blockages. 2.7 Meters: When produce such as
oil and gas, are ready for export from the production installation,
it goes through meters, which are used to manage and monitor the
volume and quantity of produce (oil and gas) transported out of the
production installation from one party to another. Specialised
meters are used to perform this process, to measure the gas
Ultrasonic meters are used and for the oil turbine meters are
used.From the diagram in Figure 1.0, the water at the bottom leaves
the separator through water dump valves installed below, which are
controlled accordingly by the water level controller at the side of
the separator as water changes are sensed. Water flows out of the
separators and heater treater as shown in figure 1.0, to the
hydrocyclones and due to pressure drops already occurred, pumps are
used for the second and third separator independently to boost its
flow to the hydrocyclones.
2.8 Pumps: This are devices which work similar to gas
compressors, with the major difference being that they are used to
impart pressure on the fluids and not gases, in order to increase
flow rate, and prevent occurrence of slippage during production.2.9
Hydrocyclones: When water enters the hydrocyclones, it removes the
oil contents from the water before sent out to sea. This process is
known as De-oiling.
i. De-Oiling: This simply means the removal of oil concentration
from water. There are many de-oiling techniques e.g. skimming tank,
corrugated interceptor, gas floatation unit etc... But
hydrocyclones are used, due to its the most common technique used
offshore, and is capable of producing oil in water disposal
standards of less than 40ppm or 40ppm which falls in line with
regulatory health and safety requirements of region, before it is
allowed to be discharged to sea.The way hydrocyclones works is it
relies on centrifugal forces to separate the light oil particles
left in the water phase as it passed through processing stages,
leaving the water to rest at the bottom and oil on top of the water
in the equipment. Water then gets collected in the water de-gassing
drum.2.10 Water De-gassing Drum: As the water is collected here, it
performs another effective process, by removing the gases still
present even as fluid has gone through various processing stages,
before the water is discharged to sea. This process is known as
De-gassing.i. De-Gassing: This simply means the removal of gas
concentration from water. A de-gassing drum is used in this
development for that purpose.The way the de-gassing drum works is,
as water enters the de-gassing drum dispersed gases slowly rise out
of it and by floatation, the gases pull along with it remaining
droplets of oil to the surface that were not separated by the
hydrocyclones. The surface oil film is drained out and channelled
back to the heater treater for dehydration, and produced now
treated water is now discharged to sea through a skim pipe.
Hydrogen sulphide and Carbon dioxide are also treated here as
explained earlier by making use of the Monoethanolamine solvent to
remove its presence.In Figure 1.0, you would have a view of the
process through which the oil flows in the separator. The oil seats
in the middle between the gas phase and water phase then it leaves
the separator through oil dump valves installed below, which are
controlled accordingly by the oil level controller at the side of
the separator as oil changes are sensed from the weir located in
the separator. The oil then flows out into a heater treater.2.11
Heater Treater: With the assumption of high viscosity crudes,
heater treater is installed in order to promote separation and fast
break out of the gas from the liquid phase. As high viscosity,
fluids have tendencies of taking longer retention time to break out
the liquid phase. This gives stabilization and dehydration of the
oil before it goes to the storage tank and then later transport. As
it is necessary for fluids to be stabilized during transport, and
gas to be dehydrated to its dew point to prevent liquid drop out
during transportation. 2.12 Storage Tank: When the oil comes into
the storage tank, it does so with the support of a pump to impart
pressure into the liquid to prevent occurrence of slippage due to
the pressure dropped already occurred in process. This device
simply stores oil produced from the fluid after it has gone through
all processing stages available and is now awaiting exportation.
RVP is carried out on the oil using Reid bomb apparatus before
transportation to ensure true vapour pressure is within range of
10-12 psia required for transport by shuttle tankers. This process
ensures vapour is not too high, as it is flammable and gives rise
to explosion hazards if escaped to atmosphere.2.13 SBM: When the
oil stored in the storage is now ready to be transported, this
provides the tankers with support during extraction as the tanker
is tied up to the SBM and through it, the tankers have the ability
to rotate around and accommodate the weather conditions present at
time of export.2.14 Shuttle Tankers: They simply are the boats,
which come and take the oil away to the storage facility when it is
ready for export.
SECTION A Part 2:3.0 Tie Back DevelopmentFor tieback in this
development, it can be performed by either introducing a new
jacket, and making use of a linking bridge to link both facilities,
Or by making use of subsea equipments for the development of the
tie back. This I believe to be a better option as the distance of
10km between both facilities is quite much for use of a linking
bridge though it cost less, the risk involved if problems were to
occur are very high. Subsea tiebacks equipments utilised are:3.1
Subsea Production Template: This support production activities to
be carried out, acting as the base foundation for other subsea
structures to be installed upon. Construction is carried out
nearby, and taken to seabed location when constructed, in which it
is gently lowered unto the seabed using a crane barge, and pile
drivers installed on it are loosened, and piled into the bottom of
the seabed to hold template in place and promote stability of the
equipment.3.2 Subsea Tree: This equipment is placed at the bottom
of the sea to seat on the template that seats on the seabed. It is
required as the final step taken for completion of a well to make
it viable for production start-up. It helps control and support the
fluid flow from the Casablanca field providing safe conduit through
it and the flow lines into the manifold.
3.3 Underwater Manifold: As described earlier this has the same
function, acts as a gathering centre and focal point for production
of fluids. It connects all series of wells together through flow
lines, while also seating on the subsea template.3.4 Multi-Phase
Meters: Also described earlier, as meters are used for many reasons
e.g. government, personal files, court cases etc. it is used to
know the quantity and volume of produce been sent out from one
party to another party.
3.5 Risers: This is a large steel pipe diameters installed, and
the function it plays is, it serves as a drill string conduit
raising and collecting fluids gathered at the seabed manifold
installed below and then sends it upwards for processing through
the subsea flow lines installed.3.6 Flow Lines: This plays the part
of conveying and transportation of oil, gas, and all other
constituents around installations, and also from the Casablanca
facility to the pre-existing Morella facility.3.7 Umbilical Cables:
These are offshore underwater cables installed and deployed into
the seabed to ensure safe transfer of electrical or hydraulic
energy to equipments used subsea.
SECTION B
4.0 Flow assurance issues faced by Casablanca and Morella
facility.Both platforms face few common flow assurance issues
likely to occur, though they may occur at different areas, they do
still occur. Moreover, some have low tendencies of occurring due to
presence of Mediterranean climate. Foreseen issues on both
platforms are:4.1 Hydrates Formation: Occurs due to physical
bonding of lighter constituents and water present in gases, and is
visible to human eyes in the form of iceberg structures. They are
formed in conditions of high pressure and low temperature, and the
risk of it occurring here are low due to Mediterranean climate but
they can still occur. If it were to occur, on the Casablanca field
it would occur on wellheads and flow lines. Then on Morella, it
would also occur on flow lines and available equipments. These plug
equipments and pipelines there by obstructing flow and causing
blockage to flow of fluids. Control Measures: If it occurred, its
controlled with use of Tri-Ethylene glycol solvent in which
performs water dehydration present in gases.
4.2 Corrosion: Occurs from the hydrates formed, but in the
presence of acid gases (Hydrogen sulphide and Carbon dioxide).
Corrosion leads to many problems such as contamination of fluids,
structural failure, rusting, and operation shutdown. On both fields
they can occur on flow lines and equipments used in the presence of
hydrates.
Control Measures: Can be controlled by making use of corrosion
resistant pipes, and through chemicals solvents such as corrosion
inhibitors like Monoethanolamine and Imodazolines4.3 Paraffin
Waxes: These are crystalline in nature, and are formed at
temperatures below cloud point. Also it has low tendency of
occurring due to Mediterranean climate. If waxes were to occur,
they would cause production choking. On both platforms, if it
occurred it would occur in flow lines. Control Measures: If it
occurred, its controlled by injection of paraffin inhibitors such
as, Ethylene vinyl acetate or Alkyl phenols or Vinyl Polymers or
through insulation of flow lines.4.4 Asphaltene Precipitation:
Formed through oxidation, in the presence of impurities along with
resins and aromatics in the crude oil, giving rise to metallic
looking molecular substances (Asphaltene). In both platforms they
can occur in flow lines, and cause the flow lines to have
depositional tendencies. Also causes reduction in diffusion rate.
Control Measures: Can also be controlled through injection of
Asphaltene inhibitors such as Aromatic solvents or Dodecyl benzene
Sulphuric Acid.4.5 Technical Advantages of Casablanca and Morella
Platform.Casablanca Platform (FPSO)Morella Platform (Tieback)
1Decommissioning of the well once depletion has occurred in
reserves is easily done, as FPSO are floating structures that can
be easily moved from Casablanca field to a new
location.Installation of the tieback from Casablanca would stop
Morella reservoir reserves from depleting in coming years and give
maximization and extension of the reservoir life span.
2They have capacities to handle more variable and large
production streams due to the availability of storage and
offloading equipments installed on-board vessels.
4.6 Technical Disadvantages of Casablanca and Morella
Platform.Casablanca Platform (FPSO)Morella Platform (Tieback)
1During exportation of produced fluids to the facility, it is
done by use of shuttle tankers, in which are constrained to weather
conditions at time of export. At a combined production rate it
would produce above 75,000 barrels per day and its more than the
required capacity. This means a delay in start date of
production
2During offloading of produce, there is risk of spillage
occurring on surface when offloading from FPSO into shuttle
tankers. As subsea equipment are utilized, it is at a major
financial disadvantage, as equipments needed for subsea operations
are very expensive to purchase.
3Presence of flow assurance issues are likely to occur such as
Asphaltene PrecipitationAfter the purchase of equipments, it is
very difficult to carry out interventions or equipment maintenance
processes if problems are to occur.
4.7 Commercial Advantages of Casablanca and Morella
Platform.
Casablanca Platform (FPSO)Morella Platform (Tieback)
1Less extra added cost involved during processing as all
requirements needed for processing, storage and transportation are
installed upon vessels.It cost a lot less to acquire as FPSO are
very expensive to rent, and also do take longer duration to
construct one together.
2It can be recycled thereby reducing cost. As at the end of its
life span, it can be converted to a tanker used in transportation
of produce (oil and gas) to locations.Compared to the FPSO this
requires a lower initial capital investment to be used in
development planning stage.
4.8 Commercial Disadvantages of Casablanca and Morella
Platform.Casablanca Platform (FPSO)Morella Platform (Tieback)
1Lesser allocation of sales returned back from the Morella
facility after sale of produce, since they possess sweet crude and
we possess sour crude so we are is contaminating the sweet crude in
their facility.Since subsea equipments are utilized, staffs would
have to be trained to achieve required competent skills in order to
be able to manage subsea equipments.
2Premium would still be paid to the Morella facility for
processing of the sour crude in the Casablanca facility. Reduction
of produce value will occur from this operation, due to the mixture
of the sweet crude in this facility with the sour crude in the
Casablanca facility, as the sour would contaminate the sweet
crude.
Section C:
5.1 Recommendation of Preferred optionAfter careful assessment
of all field development options, I do recommend the use of option
1 that is the wellhead jacket and FPSO structure over option 2 for
four main reasons, which are:
i. FPSO are very flexible structures, can be used on subsequent
upcoming projects immediately after decommissioning of one, and
even can be used on tieback development as well. ii. In option 2,
there would be a delay in cash flow, because engineers would have
to wait for a couple of years before production can commence at its
full capacity, or they can decide to start production and later on
choke wells. Nevertheless, this has effects on the flow of
cash.iii. From option 2, there would be a decrease in revenue when
making use of it, because measuring meters are not 100 percent
accurate iv. Use of option 2, has technological requirements as
subsea expertise and costly subsea interventions are
needed.ReferencesDEVOLD H., 2013. An Introduction to Oil and Gas
Production, Transport, Refining and Petrochemical Industry Oil and
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Gas. ISBN 978-82-997886-3-2.
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82921 0 (Paperback).Bibliography Robert Gordon University Campus
Moodle "Gas Sweeting Notes".Robert Gordon University Campus Moodle
"Separator Systems Notes".Robert Gordon University Campus Moodle
"Oil Treating Notes".Robert Gordon University Campus Moodle
"Produced Water Treatment Notes".Abbey-Hart Reginald Page 20
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