SURFACE PRODUCTION OPERATIONS - INTRODUCTION TO SURFACE PROCESSING2 min - THERMODYNAMIC PHASE EQUILIBRIUM5 min - UNIT OPERATIONS8 min - FLOW OPTIMISATION5.

SURFACE PRODUCTION OPERATIONS

- INTRODUCTION TO SURFACE PROCESSING 2 min- THERMODYNAMIC PHASE EQUILIBRIUM 5 min- UNIT OPERATIONS 8 min- FLOW OPTIMISATION 5 min

20 min

G.S.RAVI SHANKAR

UPES

INTRODUCTION TOSURFACE PROCESSING 2 MINUTES

Topside crude processing

CV13

LT LIC

CV18

CV12

CV19

CV11CV10

PT

PIC

CV9

CV17CV16 PIC

CV15

PT

CV14

TT

TIC

TT

TIC

CV7

LT LIC

CV6CV5CV4

Gas treatment

plant

PIC

PT

LT LIC

PIC

PT

CV20

PT

PIC

Gas pipeline transportto export station

Liquid pipeline transportexport station

25 Km

20 Km

Slug CatcherCrude oil

HP separatorP = 20 barT = 40 C

LP separatorP = 10 barT = 45 C

Flare System

Steam in

Steam out

Steam in

Steam out

NRV

Pumping stationWater treatment

plant

Compressor station

Hydrocyclone

strainer

CV3

Well Head Manifold

CV1 CV2

Water disposal, 25 ppm

Productionof oil

75000 BPD(given)

App. Productionof gas,

41.4 MMcfd(calculated)

K7O – Group H131

PTPIC

LICLT

LIC

LT

Vessel

Level Controller

Pressure controller

Feed stream

Water stream

Oil stream

Gas stream

Heat exchanger

Flare system

CV8

Control valve

ESD valve, Powered valve

Pressure relief valve

Uni

form

flow

Slu

ggis

h flo

w

CV21

CV22

Non return valve

Upstream processing

THERMODYNAMIC PHASE EQUILIBRIUM 5 MINUTES

Reservoir Classification & Phase Behavior

Oil Reservoir

Gas Reservoir

Classification

AA’ BB’ CC’ DD’ EE’

Reservoir type

Under saturated Black oil

Saturated Black oil

Retrogade Gas condensate

Wet gas Dry gas

GOR 200 - 700 2000 – 3200 8,000 – 70,000 60,000 – 100,000

> 100,000

Bo < 1.2 < 2 - - -

API 15 - 40 45 - 55 50 60 65

Liquid Vol.VsPressure

Negligible Oil + Gas + Water

Gas + Water

Crude color Dark Brown Greenish

Orange

Water White Liquid

Water White Liquid

Invisible Gas

P-V-T Phase Behavior

Pure componentHydrocarbon

Mixture

Adiabatic Flash EquilibriumV

apor

- L

iqui

dV

apor

– O

il -

Wat

er

Algorithm for calculating Mole fractions for Gas – Oil - Water

PROPERTIES & FLOW RATES

PROPERTIES FLOWRATES

DENSITY OIL STREAM

VISCOSITY GAS STREAM

THERMAL CONDUCTIVITY WATER STREAM

UNIT OPERATIONS 8 MINUTES

SeparatorsPipelinesPumpsValvesHeat ExchangersProcess controls

Separators

CV13

LT LIC

CV18

CV12

CV19

CV11CV10

PT

PIC

CV9

CV17CV16 PIC

CV15

PT

CV14

TT

TIC

TT

TIC

CV7

LT LIC

CV6CV5CV4

Gas treatment

plant

PIC

PT

LT LIC

PIC

PT

CV20

PT

PIC

Gas pipeline transportto export station

Liquid pipeline transportexport station

25 Km

20 Km

Slug CatcherCrude oil

HP separatorP = 20 barT = 40 C

LP separatorP = 10 barT = 45 C

Flare System

Steam in

Steam out

Steam in

Steam out

NRV

Pumping stationWater treatment

plant

Compressor station

Hydrocyclone

strainer

CV3

Well Head Manifold

CV1 CV2

Water disposal, 25 ppm

Productionof oil

75000 BPD(given)

App. Productionof gas,

41.4 MMcfd(calculated)

K7O – Group H131

PTPIC

LICLT

LIC

LT

Vessel

Level Controller

Pressure controller

Feed stream

Water stream

Oil stream

Gas stream

Heat exchanger

Flare system

CV8

Control valve

ESD valve, Powered valve

Pressure relief valve

Uni

form

flow

Slu

ggis

h flo

w

CV21

CV22

Non return valve

Design considerations

Design Inputs

Algorithm for Separation design using DSM

Droplet Settling Method

Results

Process piping & pumpingValvesHeat exchangers

Unit Operations

CV13

LT LIC

CV18

CV12

CV19

CV11CV10

PT

PIC

CV9

CV17CV16 PIC

CV15

PT

CV14

TT

TIC

TT

TIC

CV7

LT LIC

CV6CV5CV4

Gas treatment

plant

PIC

PT

LT LIC

PIC

PT

CV20

PT

PIC

Gas pipeline transportto export station

Liquid pipeline transportexport station

25 Km

20 Km

Slug CatcherCrude oil

HP separatorP = 20 barT = 40 C

LP separatorP = 10 barT = 45 C

Flare System

Steam in

Steam out

Steam in

Steam out

NRV

Pumping stationWater treatment

plant

Compressor station

Hydrocyclone

strainer

CV3

Well Head Manifold

CV1 CV2

Water disposal, 25 ppm

Productionof oil

75000 BPD(given)

App. Productionof gas,

41.4 MMcfd(calculated)

K7O – Group H131

PTPIC

LICLT

LIC

LT

Vessel

Level Controller

Pressure controller

Feed stream

Water stream

Oil stream

Gas stream

Heat exchanger

Flare system

CV8

Control valve

ESD valve, Powered valve

Pressure relief valve

Uni

form

flow

Slu

ggis

h flo

w

CV21

CV22

Non return valve

Process piping and pumping

LiquidPipeline Design

GasPipeline Design

Pump Design

Valve Design

Heat ExchangerDesign

Heat ExchangerDesign

FLOW ASSURANCE

Ensure pumps run at Best efficiency point (BEP)

Flow Modeleling while ensuring proper Flow characteristics for Piping components like Pumps, valves, flowmeters etc.

Type of flow in wells

FLOW ASSURANCE

FLOW ASSURANCE

Valve selection for specific purpose

FO, FC Initial Half open Additional flow

accommodation for tuning valve +/- 10% to catch slugging

Other Major Considerations ForTopside Design

TO MEET CUSTOMER DEMANDS FOR GAS & OIL COMPOSITION (Thermodynamic PVT adjustments)

REDUCE F-F MINIMUM PIPING LENGTHS (Installing efficient Instruments that require least Upstream & Downstream piping lengths)

References

Separator – Ken Arnold & Maurice Stewart, Surface production operations Vol I, ISBN: 0-88415-821-7