Oil and Gas Facilities Engineering Coursework

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 Location 60 kilometres away from nearest land fall;

Field Water Depth 300 feet deep;

Number of wells planned 5 wells;

Rate Predicted for Production 30,000 bbls oil quantity per day;

Field life Duration expected 10 years;

Depth of reservoir 12,000 feet;

Initial Pressure 6,000 psia

Pressure of oil bubble point 3,500 psia

Quality of Crude Sour – 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 CONTENTS

EXECUTIVE SUMMARY................................................................................3

INTRODUCTION..........................................................................................51.1 Aims of this report.............................................................................51.2 Objectives of this report....................................................................61.3 Assumptions taking during Development.........................................6

SECTION A:.................................................................................................72.0 Analysis for Field Development.........................................................72.1 Well Head:.........................................................................................82.2 Manifold............................................................................................82.3 Separator:.........................................................................................82.4 Gas Scrubber:...................................................................................92.5 Compressor:......................................................................................92.6 Gas Conditioning Unit:......................................................................92.7 Meters:............................................................................................102.8 Pumps:............................................................................................102.9 Hydrocyclones:................................................................................112.10 Water De-gassing Drum:...............................................................112.11 Heater Treater:.............................................................................122.12 Storage Tank:................................................................................122.13 SBM:..............................................................................................122.14 Shuttle Tankers:............................................................................12

SECTION 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:.........................................................................133.5 Risers:.............................................................................................143.6 Flow Lines:......................................................................................143.7 Umbilical Cables:.............................................................................14

SECTION B................................................................................................144.0 Flow assurance issues faced by Casablanca and Morella facility... .144.1 Hydrates Formation:.......................................................................144.2 Corrosion:........................................................................................154.3 Paraffin Waxes:...............................................................................154.4 Asphaltene Precipitation:................................................................154.5 Technical Advantages of Casablanca and Morella Platform............164.6 Technical Disadvantages of Casablanca and Morella Platform.......164.7 Commercial Advantages of Casablanca and Morella Platform........174.8 Commercial Disadvantages of Casablanca and Morella Platform....17

Section C:.................................................................................................185.1 Recommendation of Preferred option.............................................18

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 report

1) 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 report

1) 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 Development

1) 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 it’s 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 Development

For 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 Imodazolines

4.3 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)

1 Decommissioning 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.

2 They 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.


1 During 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

2 During 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.

3 Presence of flow assurance issues

are likely to occur such as

Asphaltene Precipitation

After 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.


1 Less 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.

2 It 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.


1 Lesser 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.

2 Premium 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 option

After 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.

References

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