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Production TechnologyPresenter: Ta Quoc Dung

Production Technology Topics

WELLPERFORMANCE

WELLCOMPLETION

PRODUCTIONENHANCEMENT/ARTIFICIAL LIFT

PRODUCTION STIMULATION

SURFACEPROCESSING

PRODUCTIONTECHNOLOGY

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PRODUCTIONPROBLEMS

WELL MONITORING,DIAGNOSIS

ANDWORKOVER

STIMULATIONAND REMEDIAL

PROCESSES

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Scope of Production Engineer

Production Engineer is responsible for the production system.

The production system describes the entire productionThe production system describes the entire production

process and includes the following principal components:

The Reservoir

The Wellbore

Production Conduit

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Wellhead, Xmas Tree and Flow Lines

Treatment Facilities

Elements of A Production Technology System

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Role of Production Engineer

Production Engineer performs tasks to achieve optimum

performance from the production system.

To achieve this the technologist must understand:To achieve this the technologist must understand:

Chemical and physical characteristics of the fluids.

System which will be utilised to control the efficient and safe

production/injection of fluids

The importance of the Production Chemistry and Flow

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Assurance input has only recently been widely

acknowledged.

Contribution to Oil Company Operations

Contributes substantially, in particular to economic

performance and cash flow.

The overall incentive will be to maximise profitabilityThe overall incentive will be to maximise profitability.

The objectives of an oil company operation could be

classified as:

Maximising magnitude and accelerating cash flow.

Minimising cost/bbl, i.e. total cost minimisation may not be

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recommended.

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Contribution to Oil Company Operations

Cash flow

The overall objectives would ideally be to maximise both

cash flow and recoverable reserves This would normallycash flow and recoverable reserves. This would normally

require maintaining the well in an operational state to

achieve:

Maximum production rates

Maximum economic longevity

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Minimum down time

Contribution to Oil Company Operations

Costs

In this category there would be both fixed and direct costs.

On this basis the production technologist would seek to:On this basis the production technologist would seek to:

Minimise capital costs

Minimise production costs

Minimise treatment costs

Minimise workover cost

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Ensuring that the company’s operation are safe, efficient

and profitable.

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Time Scale of Involvement

Specialist task teams to fields or groups of wells i.e. field

groups or asset teams.

Specialist groups or individual who provide specificSpecialist groups or individual who provide specific

technical expertise.

This ensure that there is a forward looking and continuous

development perspective to field and well developments.

The production engineer is involved in the initial well design

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p g g

and will have interest in the drilling operation from the time

that the reservoir is penetrated.

Time Scale of Involvement

The inputs of production engineer will last throughout the

production life of the well, to its ultimate abandonment.

The production engineer will contribute to companyThe production engineer will contribute to company

operations on a well from initial planning to abandonment.

The inputs in chronological order to the development and

the operation of the well are listed below.

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Time Scale of InvolvementDrilling

Casing string design.

Drilling fluid selection.

Completion

Design/installation of completion string.

Production

Monitoring well and completion performance.

Workover/re-completion

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Diagnosis/recommendation/installation of new or improved production

systems.

Abandonment

Identify candidates and procedures.

Questions

1. Which company is producing oil the most in Vietnam?

What is its average day-rate?

2 Locate main oil and gas production fields in Vietnam?2. Locate main oil and gas production fields in Vietnam?

3. Name some oil refinery projects in Vietnam?

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Ch t 2Chapter 2

Process Overview

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Content

sOnshore

Offshore

Wellhead

Manifold/Gathering

Separator

Gas Compressor

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p

Pipeline

Metering, Storage and Export Facilities

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Basic Process Scheme

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Process OverviewProductionWellheads

Productionand TestManifolds

Gas Compressor Metering andStorage

Export

Production Separators PigLauncher

PigLauncher

GasPipeline

OilPipeline

LP HP Gas Meter

p

Test SeparatorOil Storage

Water Treatment

1-Stage

2-StageCrudePump

OilMeter

TankerLoading

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Drilling

InjectionWells

InjectionManifolds

Mud and Cementing

Utility Systems (selected)

Water injectionpump

Gas injectioncompressor

Power Generation

Instrument Air

Potable Water

FirefightingSystems

HVAC

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Oil and Gas Production

Oil and gas is produced in almost every part of the world.

Production from 100 bbl/day to 4000 bbl/day per well.

Depth of production from 20 m to 3000 m and moreDepth of production from 20 m to 3000 m, and more.

Current trend of petroleum production:

Explore reservoirs at ultra high water depth.

Develop subsea production system.

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Production System

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1. Onshore well

2. Fixed, multi platform

3. Fixed, self-contained platform

4. Self-contained, concrete gravity platform

5. Floating, single point mooring

6. Storage/shuttle tanker

7. Floating, tension leg platform

8. Subsea manifolds

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Offshore

Facilities selected depending on:

Type of fluid: oil, gas or condensate.

Production rate.

Location of field and water depth.

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Offshore Production System

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Type of Offshore Platform

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Type of Offshore Platform (cont.)

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Type of Offshore Platform (cont.)1353 ft(1991)

1754 ft(1998)

4674 ft(2004)

5610 ft(2004)

6300 ft(2003)

4429 ft(2005)

7570 ft(2004)

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Shallow Water Complex

Water depth up to 100 m.

Several independent platforms with different parts of the

process and utilities linked with gangway bridgesprocess and utilities linked with gangway bridges.

Individual platforms will be described as:

Wellhead Platform

Riser Platform

Processing Platform

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Accommodations

Platform and Power

Generation Platform

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Integrated Steel Jacket Platform

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Gravity Base

Water depth: 100 – 500 m.

Concrete fixed structures

placed on the bottom typicallyplaced on the bottom, typically

with oil storage cells.

Large desk receive all parts of

the process and utilities.

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Compliant Tower

Water depth 500 – 1000m.

Much like fixed platforms, consist of narrow tower attached

to a foundation on the seafloor and extending up to theto a foundation on the seafloor and extending up to the

platform.

Compliant tower is quite flexible.

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Compliant Tower

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Moving a compliant tower

to a field.

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Rig-up

Fixed platforms are built in

onshore bases.

Then they are towed to theThen they are towed to the

field by tugboats.

Platforms positioned and

connected to seafloor.

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Floating Production

All topside system are located on a floating structure.

Floaters:

FPSO - Floating Production Storage and Offloading 200-2000 mFPSO - Floating Production, Storage and Offloading, 200-2000 m.

TLP – Tension Leg Platform, up to 2000 m.

SPAR – single tall floating cylinder hull, 300 – 3000 m.

Turrets are positioned by:

POSMOR (position mooring): chain connections to anchors.

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DYNPOS (dynamic positioning): thrusters and propellers.

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FPSO

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FPSO with Tanker

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TLP

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TLP with subsea wells

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SPAR

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SPAR anatomy

1. Monocolumn Hull

2. Tendon Porches

3 Tendons3. Tendons

4. Foundation

5. Deck

6. Hull to Deck Transition

7 Ri P h

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7. Riser Porch

8. Riser/Umbilical Pull Tubes

9. Moonpool

10.Production Risers

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Subsea Production System

Typically used at 7000 ft depth or more.

Drilling and completion are performed from a surface rig.

Wells located on the sea floorWells located on the sea floor.

Petroleum is extracted at the seafloor, then “tied-back” to

an existing production system by subsea pipeline and riser.

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Subsea FPSO Development

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Host Platform connected to several Subsea Fields

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Main Process Section

An oil and gas production system consist of the main

following sections:

WellheadWellhead

Manifold/Gathering

Separator

Gas compressor

Pipeline

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Some optional facilities may be required

Heat exchanger

Scrubber and Reboiler

Wellhead

Located on top of the well, also called “The X-mas tree”.

Allow a number of operations relating to production and

workover Workover refers to various technologies forworkover. Workover refers to various technologies for

maintaining the well and improving production.

Control the flow of the well with a choke.

Two main type of wellheads:

Dry completion: conventional wellheads.

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y p

Subsea completion: subsea wellheads.

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Wellhead

AS T

REE

TUB

ING

HEA

DX-

MA

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CAS

ING

HEA

D

Wellhead (cont.)

A wellhead consists of three component:

Casing head: where casing are bolted or welded to casing hanger.g

Tubing head: used to position the tubing correctly in the well.

X-mas treeMaster gate valve: high quality valve, not used to control flow.

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Pressure gauge: may also fitted together with temperature gauge.

Wing valve: when shut in, tubing pressure can be read.

Swab valve: access to the well for wireline operations, etc…

Choke: made of high quality steel, used to control the flow.

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Subsea Wellhead

Placed in subsea structure.

World deepest subsea production tree is 9000 ft of water.

Compact system function similar to conventional wellheadCompact system, function similar to conventional wellhead.

Operated by ROV

(remote operated vehicle).

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Subsea Wellhead (cont.)

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History of Subsea Technology

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ROV

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Types of Choke

Principal surface system pressure loss occurred at choke.

Choke is designed to control the well flow rate and

pressure before fluid exposed to surface equipmentpressure before fluid exposed to surface equipment.

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Manifold/Gathering

Every individual well is brought in to the main production

facilities over a network of gathering pipelines and manifold

systems.systems.

Manifolds allow to set up and control production of a “well

set” and utilize reservoir.

Manifolds can be placed on surface, on platform or on

seafloor, depending on the production system.

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Manifolds

Manifolds Subsea manifolds

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Separator

Production fluid of a well may consist of gas, oil, water,… and must be separated and processed.

Separator form the heart of the production process.p p p

When fluid fed into a separators:Pressure is controlled and reduced in several stages

After a retention time, gas bubble out, water settle at the bottom and oil stay in the middle.

There are 2 types of separator:

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There are 2 types of separator:Gravity separators,

Centrifugal separators: in which the effect of gravity is enhanced by spinning the fluids at a high velocity.

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Gravity SeparatorsWorking on the density difference between the phases be separated.

Cylindrical vessel up to 5m in diameter and 20m long.

Either 2-phase or 3-phase.

Normally mounted in a series of 2, 3, or even 4 separators.

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3-phase Horizontal Gravity Separator

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3-phase Vertical Gravity Separator

Tend to be larger

than a horizontal

separator for theseparator for the

same separation

capacity due to

smaller interface

areas.

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Gas Compressor

Gas from a pure natural gas wellhead might have sufficient

pressure to feed directly into a pipeline transport system.

Gas from separators has generally lost so much pressureGas from separators has generally lost so much pressure

that it must be recompressed to be transported.

Typical gas compressor is turbine compressor, which

contains a type of fan that compresses and pumps the

natural gas through the pipeline.

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Gas Compressor (cont.)

Compressor power is often delivered by gas turbines,

diesel engines or electric motor, depending on location and

power required.power required.

Types of compressor:

Centrifugal compressor

Positive displacement reciprocating compressor.

Both compressor types are susceptible to damage by liquid

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droplets, hence the presence of the liquid knockout vessels prior to each compressor.

Simplified Processing Oil Facilities Scheme

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Pipeline

Pipeline exists everywhere in a production system.

Many types of pipe and flowline are used in transportation

of oil and gas diameters vary from 6” to 48” and moreof oil and gas, diameters vary from 6 to 48 and more.

Due to oil and gas properties and harsh environment,

production pipeline has special construction and design.

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Layers of a Production Line

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1. Carcass

2. Inner liner

3. Pressure armour

4. Tensile armour5. Outer sheath

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Heat Exchanger

For a compressor operates in an efficient way, the

temperature of the gas should be low.

Heat should be conserved e g by using cooling flood fromHeat should be conserved, e.g. by using cooling flood from

the gas train to reheat oil in the oil train.

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Scrubber and ReboilerUsed to remove small fraction of liquid from the gas before it reaches the

compressor. Liquid droplets can erode the rotating blades if they enter the

compressor.

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Metering

Several metering devices are used in every petroleum

production system to measure gas or oil properties as it

flows through the pipeline.flows through the pipeline.

Metering stations allow operators to monitor and manage

the natural gas and oil flow without impeding its movement.

Typically, a metering installation consists of a number of

meter runs and associated prover loops so that the meter

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accuracy can be tested and calibrated at regular intervals.

Oil metering Gas metering

Storage

Gas is usually not allowed to storage on platform.

Oil is often stored before loading on a vessel.

Offshore production facilities without a direct pipelineOffshore production facilities without a direct pipeline

connection rely on crude storage in the base or hull and

allow a shuttle tanker

to offload periodically.

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A Base at Night

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Export of Oil

The volume of oil being exported has to be measured to the

highest accuracy.

Pipeline requires regular cleaning to ensure its efficientPipeline requires regular cleaning to ensure its efficient

operation. A “pig” is usually used to remove settled sand,

wax deposit, stagnant water,…

Offshore, loading on tankers involve loading systems,

ranging from tanker jetties to sophisticated single point

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mooring and loading systems that allow the tanker to dock

and load product even in bad weather.

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Export - FPSO Offloading to a Tanker

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Export of Gas

Gas has to pass several process and treatment before

exporting to customers, including:

SeparationSeparation

Compression

NGL stabilization

Dehydration

Acid gas treating

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These processes may repeat to improve the purity of gas

and control gas properties.

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Gas Field Facilities

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Export - Gas Transportation

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Export - Gas Transportation (cont.)

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Produced Water TreatmentProduced water, after separation and treatment, is normally disposed of by injection into disposal wells, reinjection into the reservoir or pumping to open pits where it is allowed to evaporate or drain.

I ff h ti th th f t th t iIn offshore operations, there are other sources of water that require treatment before disposal:

Water used for washing / cleaning of equipment,

Sea spray and rain water,

Utility water previously used for heating and cooling duty,

Displacement water from crude oil storage systems and shuttle tankers.

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At some offshore locations if the environmental regulations permit it, oil-free water may simply be pumped into the ocean.

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Produced Water Treatment (cont.)

Primary separation may be enhanced by:

1. Heating of the crude oil: to reduce viscosity.

2. Addition of demulsification chemicals: to alter the interfacial tension

between the oil droplets and the water.

3. Electrostatic separation: to further reduce the water content of

relatively dry oil. The water droplets suspended in the oil carry a small

electrical charge and by imposing the appropriate electrical field across

(part) of the settling region inside the separator, the settling rate of

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water will increase. This method is not widely used but is occasionally

employed in conjunction with the more difficult to separate, typically

denser, crude oils.

After above methods, oil content in water is still about 500 – 2000 ppm.

Produced Water Treatment (cont.)

Further treatments are applied to reduce oil content down to 40 ppm average, which is required by legistration in many countries.

Many schemes have been developed to reduce this oil content:

1. (Corrugated) Plate Interceptors

2. Flocculation / Coagulation

3 Flotation

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3. Flotation

4. Hydrocyclones

5. Coalescer Units

6. Centrifuges

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(Corrugated) Plate Interceptors (T chắn)Reducing the distance required for a droplet to migrate before it comes

into contact with other oil droplets and coalesces.

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Flocculation (k’ bông)/ Coagulation (đông)Uses a chemical (such as Ferrous Sulphate) which forms a voluminous

precipitate in contact with water, artificially increasing suspended liquid

size and their ability to coalesce.

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Dispered Gas Flotation (tách khí phân tán)Gas injected into the water and dispersed by a rapidly rotating impeller,

rising gas bubbles attaching themselves to the oil droplets.

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Dissolved Gas FlotationGas dissolved in the water under high pressure. When pressure is rapidly

reduced - by passage of the water through a throttling valve - gas comes

out of solution in the form of many small bubbles (champagne bottle

effect).

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HydrocyclonesStandard device for cleaning oily water,

developed in the early 1990s.

Using centrifugal force to increase the

effect of gravity separation.

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Coalescer Units (thiết bị thu gom dầu)

Provide a (usually oleophilic) surface on which the small

droplets of oil can collect, grow and eventually break free

and be removed for subsequent separation.and be removed for subsequent separation.

Can produce the lowest oil concentrations (5 ppm oil in

water has been achieved in ideal circumstances).

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Centrifuges

The principle of enhanced gravitational force employed by

Hydrocyclones can be further extended by use of

centrifuges where an external electric motor is used to spincentrifuges where an external electric motor is used to spin

the fluid at high velocity together with a suitably designed

internals to promote oil/water separation.

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Modern Scheme for Clean Produced Water

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Utility SystemsUtility systems are systems that does not handle the hydrocarbon process

flow, but provides some utility to the main process safety or residents.

1. Control and Safety Systems

1. Process Control Systems

2. Emergency Shutdown and Process Shutdown

3. Control and Safety Configuration

4. Fire and Gas Detector System

5. Telemetry

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y

6. Condition Monitoring and Maintenance Support

7. Production Information Management System (PIMS)

8. Training Simulator

Example of Process Control System

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Utility Systems2. Power Generation and Distribution

3. Flare and Atmospheric Ventilation

4. Instrument Air

5. HVAC (heat, ventilation, air conditioning system)

6. Water System

1. Portable water

2. Sea water

3 Ballast water

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3. Ballast water

7. Chemical and Additives

8. Telecom

Questions

1. Which is more expensive, production onshore or offshore?

Why?

2 Why did the oil industry start drilling and production2. Why did the oil industry start drilling and production

offshore?

3. What are the main differences between oil production and

gas production?

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