Oil and Gas Production

Oil and Gas Industry Overview (UPSTREAM)

Source: Methane to Markets, Oil & Gas Industry Overview

Production Flow Diagram

Source: Oil & Gas Production Handbook , ABB

Separation

WELL FLUIDS & WELL CLASSIFICATION

Wells are generally classified according to the type of fluid they produce in the greatest quantity.
FLUIDS IN RESERVOIR FLUIDS IN FLOW LINE PROCESSING STEPS WHICH MAY BE REQUIRED

CLASS OF WELL

DRY GAS

GAS, POSSIBLY WATER

GAS, POSSIBLY WATER CRUDE OIL, POSSIBLY GAS POSSIBLY WATER

GAS, POSSIBLY WATER

GAS CONDENSATE, POSSIBLY WATER CRUDE OIL, POSSIBLY GAS, POSSIBLY WATER

SEPARATION, GAS DEHYDRATION

SEPARATION, GAS & CONDENSATE DEHYDRATION SEPARATION, GAS DEHYDRATION

GAS CONDENSATE

CRUDE OIL

Source: http://articles.compressionjobs.com/articles/oilfield

Reservoir pressures are generally much higher than atmospheric pressure. As well fluids reach the surface, pressure on them is decreased. The liquid ability to hold gas in solution decreases, and the liquids begin to release 'Solution Gas'.

In summary, there are variables which aid in the separation of a fluid stream. Temperature of the fluids. Pressure on the fluids. Density of the components.

Source: http://articles.compressionjobs.com/articles/oilfield

Separator
A SEPARATOR is a vessel in which a mixture of immiscible fluids are separated; e.g. Crude oil, Natural gas and Water. A separator may be a 'Horizontal', 'Vertical' or 'Spherical' vessel. Fluid flow from a well can include gas, free water, condensable vapours (water or hydrocarbons), crude oil, and solid debris (basic sediment). The proportion of each component varies in different well streams. Although most separators are two -phase in design, separating the gas and total liquids, three - phase vessels can be built to separate natural gas, oil or other liquid hydrocarbons, and free water.

Source: http://articles.compressionjobs.com/articles/oilfield

SEPARATOR FUNCTIONS
A well stream separator must perform the following: Cause a primary phase separation of the liquid hydrocarbon from those that are Gas. Refine the primary separation by removing most of the entrained liquid mist from the gas. Further refine the separation by removing the entrained gas from the liquid. Discharge the separated gas and liquid from the vessel and ensure that no reentrainment of one into the other takes place.

Source: http://articles.compressionjobs.com/articles/oilfield

The main principles used to achieve physical separation of gas and liquids are: GRAVITY SETTLING and COALESCING Any separator may employ one or more of these principles, but the fluid phases must be 'Immiscible' (cannot mix), and have 'Different Densities' for separation to occur

Separation vessels usually contain four major sections, plus the necessary pressure and liquid level controls. These sections are: 1. Primary Separation Section 2. Secondary Separation Section 3. Mist Extraction Section 4. Liquid Accumulation Section

Source: http://articles.compressionjobs.com/articles/oilfield

TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Vertical

Source: http://articles.compressionjobs.com/articles/oilfield

TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Horizontal

Source: http://articles.compressionjobs.com/articles/oilfield

TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Tangential or Cyclone

Source: http://articles.compressionjobs.com/articles/oilfield

TYPES OF SEPARATOR
LIQUID / LIQUID SEPARATORS- Coalescer

Source: http://articles.compressionjobs.com/articles/oilfield

Separation
Test Separators and Well test Production separators (First Stage) Second stage separator Third stage separator Coalescer Electrostatic Desalter Water treatment

Source: Oil & Gas Production Handbook , ABB

Gas Treatment and Compression

HEAT EXCHANGER
Heat transfer is a process by which internal energy from one substance transfers to another substance. Usually from a body at higher temperature to a body at lower temperature.

Source: Wikipedia

Modes of Heat Transfer

Conduction Convection Radiation

Source: Wikipedia

Heat exchangers are devices used to transfer heat energy from one fluid to another

Types of Heat Exchangers: Shell and Tube Plate Type Double Pipe Spiral Regenerative Source: http://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-

BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdf

SHELL AND TUBE HEAT EXCHANGER

It is the most common type of heat exchanger in oil refineries and other large chemical processes Suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle, and may be composed by several types of tubes: plain, longitudinally finned, etc.

Source: http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx

Source: http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx

Tube Bundle

Source: Heat Exchangers, Types and Applications Cairo University, Faculty of Engineering, Chemical Engineering Department

Baffle Arrangement

Source: Heat Exchangers, Types and Applications Cairo University, Faculty of Engineering, Chemical Engineering Department

Source: http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/

PLATE AND FRAME HEAT EXCHANGER

A plate type heat exchanger, consists of plates instead of tubes to separate the hot and cold fluids. The hot and cold fluids alternate between each of the plates. Baffles direct the flow of fluid between plates. Because each of the plates has a very large surface area, the plates provide each of the fluids with an extremely large heat transfer area. Therefore a plate type heat exchanger, as compared to a similarly sized tube and shell heat exchanger, is capable of transferring much more heat. This is due to the larger area the plates provide over tubes. Due to the high heat transfer efficiency of the plates, plate type heat exchangers are usually very small when compared to a tube and shell type heat exchanger with the same heat transfer capacity. Plate type heat exchangers are not widely used because of the inability to reliably seal the large gaskets between each of the plates. Because of this problem, plate type heat exchangers have only been used in small, low pressure applications such as on oil coolers for engines. However, new improvements in gasket design and overall heat exchanger design have allowed some large scale applications of the plate type heat exchanger

Source: http://www.engineersedge.com/heat_exchanger/plate.htm

Source: http://www.engineersedge.com/heat_exchanger/plate.htm

Source: Heat Exchangers, Types and Applications Cairo University, Faculty of Engineering, Chemical Engineering Department

Source: Heat Exchangers, Types and Applications Cairo University, Faculty of Engineering, Chemical Engineering Department

Source: Heat Exchangers, Types and Applications Cairo University, Faculty of Engineering, Chemical Engineering Department

SCRUBBERS & REBOILERS

Source: Oil and Gas Production Handbook, ABB

COMPRESSORS
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. Compressors are driven by gas turbines or electrical motors (for lower power also reciprocating engines, steam turbines are sometimes used if thermal energy is available). Often several stages in the same train are driven by the same motor or turbine

Source: http://en.wikipedia.org/wiki/Gas_compressor

TYPES OF COMPRESSORS
PARAMETERS
Build

RECIPROCATING COMPRESSORS
A piston and cylinder design with 2-2 cylinders

SCREW COMPRESSORS
Two counter rotating screws with matching profiles provide positive displacement and a wide operating range.

AXIAL BLADE COMPRESSORS

Axial blade and fin type Compressors with up to 15 wheels provide high volumes at relatively low pressure differential (discharge pressure 3-5 times inlet pressure)

CENTRIFUGAL COMPRESSORS
Centrifugal compressors with 3-10 radial wheels, Pressure differential up to 10.

Power (MW) Synchronous Speed (rpm) Pressure Used for

30 MW 500-800

up to several MW 3000/3600 5000-8000

Upto 80 MW 6000 20000 (highest for small size) Upto 50 bars Air compressors and cooling compression in LNG plants Larger oil and gas installations

5 MPa Lower capacity gas compression and high reservoir pressure gas injection

2.5 MPA (25 bars) Typical use is natural gas gathering.

Source: Oil and Gas Production Handbook, ABB

Reciprocating Compressor

Screw Compressors

Centrifugal Compressors

Axial Blade Compressors

Source: Oil and Gas Production Handbook, ABB

Performance Control
The object of the compressor performance control is to keep the operating point close to the optimal set point without violating the constraints, by means of control outputs, such as the speed setting. However gas turbine speed control response is relatively slow and even electrical motors are not fast enough since the surge response must be in the 100 mS range. The anti surge control will protect the compressor from going into surge by operating the surge control valve. Basic strategy: to use distance between operating point and surge line to control the valve with a slower response time starting at the surge control line. Crossing the surge trip line will control a fast response opening of the surge valve to protect the compressor. Compressor maintenance intensive: Load management Vibration Speed governor

Source: Oil and Gas Production Handbook, ABB

Chemical & Additives

Wide range of chemicals used in various processes in production of crude oil.

Scale Inhibitors:
Well flow contains Contaminants like Salt, chalk, traces of radioactive elements precipitates due to the change in temperature and pressure and get stuck or clog up in the pipes, heat exchangers, values. Helps in preventing the contaminants spreading out. Added on well heads & production equipments.

Emulsion Breaker :
The layer formed between oil and water is emulsion. We need to separate both and extract oil. Added to prevent the formation and breakdown of emulsion layer. Sand and other particles will be absorbed by water.

Sources : Oil & gas handbook production ABB, Wikipedia

Antifoam

Foam is produced in the separator .This foam will cover the fluid surface and block the gas to escape, reduces the gas space inside the separator. Escapes through demister as mists & vapors. Antifoam agent introduced in the upstream of separator to prevent or break down foam formation.

Source :Oil & gas Handbook ABB

Methanol :
Injected in flow lines to prevent hydrates formation and corrosion Hydrates are crystalline compounds that form in water crystalline structures as a function of composition, temperature and pressure. Hydrates might form and freeze forming hydrate ice, that may damage pipes and equipments. Hydrates prediction model software can be used to determine when there is a risk of hydrate formation or to reduce methanol injection or delay pressurization

Drag Reducers :
In pipe lines oil flow near the pipe will be less and the flow at centre will be high ,causing turbulent bursts resulting turbulent eddies. drag reduction polymers suppress the turbulent bursts, which improves flow in pipelines.

Sources : Oil & gas handbook production ABB, Wikipedia

GAS TREATMENT
When the gas is exported, many gas trains include additional equipment for further gas processing, to remove unwanted components such as hydrogen sulfide and carbon dioxide. These gases are called acids and sweetening /acid removal is the process of taking them out. Natural gas sweetening methods include absorption processes, cryogenic processes; adsorption processes and membranes. Often hybrid combinations are used, such as cryogenic and membranes.

Source: Oil and Gas Production Handbook, ABB

Oil & Gas Storage, Metering and Export

Oil and Gas Storage, Metering and Export

The final stage before the oil and gas leaves the platform consists of storage, pumps and pipeline terminal equipment.

Oil and Gas Metering

Fiscal Metering Partners, authorities and customers all calculate invoices, taxes and payments based on the actual product shipped out. Often custody transfer also takes place at this point, means a transfer of responsibility or title from the producer to a customer, shuttle tanker operator or pipeline operator.

Sources: Oil and gas production handbook; ABB http://www.standard.no/PageFiles/1224/I-SR-104r1.pdf

Metering System Contd.

Analyzer
The analyser instruments provides product data such as density, viscosity and water content. Pressure and temperature measurement is also included. For liquid, turbine meters with dual pulse outputs are most common The metering is split into several runs, and the number of runs in use depends on the flow. Each run employs one meter and several instruments to provide temperature and pressure correction Open/Close valves allow runs to be selected and control valves can balance the flow between runs.

Sources: Oil and gas production handbook; ABB

Metering System

Sources: Oil and gas production handbook; ABB http://instrumenttoolbox.blogspot.com/2011/05/how-to-construct-instrument.html

Gas metering
Gas metering is similar, but instead, analysers will measure hydrocarbon content and energy value (MJ/scm or BTU, Kcal/scf) as well as pressure and temperature. The meters are normally orifice meters or ultrasonic meters. Different ranges are accommodated with different size restrictions. The pressure differential over the orifice plate as well as pressure and temperature is used in standard formulas to calculate normalized flow. Larger new installations therefore prefer ultrasonic gas meters that work by sending multiple ultrasonic beams across the path and measure the Doppler Effect.

Sources: Oil and gas production handbook; ABB

LNG metering
LNG is often metered with massflow meters that can operate at the required low temperature. However recently Ultrasonic flow meters are being used, which offer the right technology and value proposition for custody-transfer applications.

Sources: www.isa.org http://www.standard.no/PageFiles/1224/I-SR-104r1.pdf