II I

SPE 36584

The Auger Platform: Debottlenecking and Expansion Of Fluid Handling Facilities

T. R. Judd, Shell Offshore Inc.; C. B. Wallace, Shell E&P Technology Co.

commenced in 1994, SOI has 100/0 interest in the leases

Ccfwwhf 1JW. Swa of Petroleum Engineers Irw
which were acquired in 1984 and 1985. The field, located
?Ws paper was prepared fw p+esenfabon at Ihe 19W SPE Annual T.chnmd Cmnfecon- in the central Gulf of Mexico in Garden Banks Blocks
and ExhMmn held m Oenver, Colorado, U.S A E9 October 19W
426, 427, 470, and 471, is approximately 214 miles
TM paper was selected W presentation by an SPE Prdgram Commmw fol!ewmg
mwew d infcmnation confanmd in an abstract submrfted by the author(s) Gmtents cd @w southwest of New Orleans and 255 miles southeast of
paper, as pm8entd, have not been rewvwed by the Sdciety of Patroleum Englneem and
am wbjod tm correction by the mdhor(s} The mateoat, as presented d- nd
Houston. Field reserves are estimated at 220 million
nocessady refleci any posdkm of the %cIefy of Petroleum Enguwers b office-, or barrels of oil equivalent. Total project cost for Auger is
members Papers presented at SPE meetmgs are subpxf b pubkcattcm r- by
Eddonal Commiifeea of fhe Smety of Pefroleum Engmears Perrmwon to copy IS approximately $1.2 billion including drilling.
restricted to an abstract of ml more than 303 words Iilustratons may not be copmd The
abstmc+ should ccotain conspicuous acknwiedgment of where and by whom the paper
was presented Wrde Librarian, SPE, P O @ax 833&6 Richardson, TX 7YMX3836 The Auger project represents Shells first application of a
U S A fax 01-214-652-8435
TLP. Until Shells Mars TLP was installed in May 1996,
Auger held the producing water depth record of 2860 tl.
Abstract for the Gulf of Mexico, and for a TLP. These records will
AUGER Shells first Tension Leg Platfom~ (TLP), was
be eclipsed during the next several years as other SOI
installed in 1994 in 2860 feet of water in the Gulf of
deepwater developments including Mensa, Rwn/Powell
Mexico. The platform was designed to process 40 MBPD
and Ursa come onstream.
of oil, 100 MMSCFD of gas, and 25 MBPD of water. For
most of its operation, the surface fluid handling facilities
Topsides Facilities
have proven to be the primary constraint limiting The Auger topsides include an integral drilling rig;
increased production.
32 well slots (24 oil/gas, 8 waterflood) around a 74 R by
Through innovative debottlenecking and expansion of the
194 R. rectangular well bay; a 140 bed quarters building;
surface facilities, Auger production rates have recently
and processing facilities for oil, gas, and produced water
increased to more than 72 MBOPD and 150 MMSCFD of
including separation, dehydration, treatment, compression
gas Further plans are underway to ultimately increase the
and utility and safety systems (e. g., flare, firewater, etc.).
total platform capacity to 100-140 MBOPD and 300-400
The original Auger design was based on production rates
MMSWD.
of 40,000 BBL/D of oil, 100 MMSCFD gas,
This paper will present the original platform design,
25,000 BBLiD produced water and planned for 60,000
describe the constraints on the facilities due to higher than
BPD of waterflood injection.
anticipated well flow rates and surface temperatures, and
The TLP is a floating structure and is subject to
discuss the steps taken to reduce the constraints and
considerably more movement than is the case with fixed
resolve most problems, These problems include: (I) poor
platforms, Critical process equipment having gas/liquid or
gadliquid separation etlciency in high pressure
Iiquidlliquid interfaces was therefore designed to
separators, (2) excessive natural gas liquid (NGL)
accommodate the effects of motion. Additionally, since
condensation in the gas export pipeline, (3) gas
the TLP is held in place by tendons, buoyancy must be
dehydration system limitation due to high rates and
provided. This places a premium on weight reduction for
surface temperatures and (4) other facilities engineering
topside facilities. Fortunately, alternative technologies
related problems,
exist which combine reduced weight and sensitivity to
motion when compared to process equipment commonly
Introduction
used on fixed platforms. Two examples include use of
Shell Offshore Inc. (SOI) completed the Auger discovery
hydrocyclone rather than induced gas flotation for
well in May 1987 and initial production from the field

135
2 THE AUGER PLATFORM: DEBOTTLENECKING AND EXPANSION
OF FLUID HANDLING FACILITIES
removal of suspended oi 1from produced waler and the use
of structured packing rather than valve or bubble cap trays
in the glycol contactor used for gas dehydration.
Figure 1 is a very simplified schematic of the original
Auger oil and gas processing facilities. Oil WC1lSproduce
a 37 API gravity oil and 0,68 gravity gas. Gas wells
produce a 42 API gravity oil and 0.65 gravity gas. The
original concept included separate high pressure
separators for oil and gas wells designed to operate at 1550
psig. Liquid from the two high pressure vessels and a
parallel Icst separator (not shown) flow to an Intermediate
Pressure (1P) separator which operates at 600-700 psig.
Oil from the [P separator next flows to a Free Water
Knock Out (FWKO) at 125 psig (there is currently no
produced water), then to a Bulk Oil Treater (BOT)
operating at 40 psig and finally to an oil tank from which
it is pumped to a 75 mile, 12 pipeline to Eugene Island
Block 331. Oil from the FWKO passes through two heat
exchangers to pick up heat from oil exiting the BOT and
from the heat media system.
Gas from the High Pressure Oil, Gas, and Test Separators
is commingled and flows to a filter separator and then to a
Tri-ethylene Glycol (TEG) contact tower where the gas is
dehydrated. Although the sales gas water specification is
7 lb/MMSCF, the gas must be dried to below 4 lb/MMSCF
to avoid hydrate formation at low Gulf bottom
temperatures in the deep water (approximately 40 degrees
F). Gas is then delivered into a 37 mile, 12 Sheli
pipeline to a platform at Vermilion Block 397 where liquid
and gas are separated, metered and then recombined and
delivered into the gas transportation companys pipeline
for transporl to shore.
Gas from the 1P and all lower pressure separators is
compressed to pipeline pressure and combined with high
pressure gas upstream of the filter separator and
dehydrator. The 2000 HP DC motordriven 4 stage
reciprocating Flash Gas Compressor (FGC) compresses
gas from the stock tank, BOT and FWKO, The final two
stages of compression are provided by a centrifugal
Booster Gas Compressor (BGC)driven by a 5000 HP gas
turbine. FGC discharge gas is routed to the first stage
BGC suction with IP separator vapors feeding the BGC
interstate. Liquids condensed in compressor discharge
coolers and separated in interstage scrubbers are reeycled
to the appropriate vessel in the oil separation train.
Production during this phase peaked out at 55,000 BOPD
and 105 MMSCFD,
Stage 1 Debottlenecking Activities - Late 1994,
Early 1995 (Figure 2)
Debottieneeking activities began in the summer of 1994
when it became apparent that the production potential of
high rate Auger wells far exceeded the handling capability
136
SPE 36564
of the surface facilities. Production from individurd oil
wells reached 12,000 BBL/D and 25 MMSCFD.
Several critical problems surfaced shortly after first
production in April 1994. These mainly had to do with
wells flowing at much higher flow rates than had been
anticipated. There were to have been 24 producing wells
with a design processing temperature of 90 degrees F.
Well temperatures were to be kept high by nitrogen in the
production tubing/casing annuhrs to insulate the fluids
from the cooling effect of seawater, thus minimizing
paraftlr and hydrate problems.
By July 1994, the production from just three wells was
27,000 BBL/D and 75 MMSCFD The surface
temperature of the wells ranged from 120-140 degrees F.
Early problems experienced included: 1) poor separation
efficiency in high pressure separators and filter separator
(collapsed filter elements, no coalescing) resulting in
carryover of oil into the glycol system, 2) high gas
temperature and related water carrying potential,
3) dehydration system problems including carryover of
glycol into the gas export line, 4) difficulty testing wells,
5) excessive condensation of liquid hydrocarbons in the
sales gas pipeline, and 6) inability to accurately prechct
facility performance with process simulation model due to
foaming in separators. The ultimate bottleneck during
most of this period was the inability of the gas pipeline
company to handle condensed liquids and oil carryover
from the HP separators, which caused fouling and foaming
of the glycol system.
To minimize surges, flow from all oil wells has been split
between both W vessels. Gas wells have been
predominantly shut in since the oil wells have been
capable of keeping the facilities and pipelines full. Also,
due to the elevated production temperatures, the heat
exchangers upstream of the BOT were bypassed.
The debottlenecking study primarily addressed facilities-
related problems at Auger which limited production rates.
This effort involved operations and engineering stalT
assigned to the Auger Project, along with Shell Head
Offke and Research engineers.
By August/September 1994, a short term debottlenecking
plan had been formulated. Gamma scan of high pressure
separators and fluid sample tests indicated that foaming
was likely oecurnng in the separation vessels and the
vane-type demisters in these vessels were largely
ineffective on foam. Tests on the HP Gas Filter Separator
located upstream of the TEG contactor indicated it was not
completely removing entrained oil carried over from high
pressure separators, This resulted in contamination of,
and resultant foaming in the glycol system.
The original design dewpoint of 2#MMSCFD for sales
gas was to be achieved through reduced gas inlet
temperature of 90 degrees F. The high well flow rates
were producing higher temperatures in the process facility
SPE 36S84 T. R JUDD AND C. B. WALLACE
and thus the polential for the gas stream to carry more
water into the TEG Contactor. To reduce the temperature
of the gas entering the TEG system, an air cooler was
installed in the high pressure gas stream. Also, the
production tubing Jcasing annulus nitrogen was displaced
with completion fluid, leading to a drop in temperature in
the well fluids of approximately 10 degrees F. Several
options were considered to improve separation efficiency
in the high pressure vessels including a retrofit with vortex
tube inlet devices, installation of internal spray nozzles to
al [eviate the foam problem and other modifications to the
vessel internals and inlet piping. The option selected was
to install a cyclone separator between the new air cooler
and the filter separator. The cyclone would recover any
liquids condensed from the gas by the air cooler plus
liquids entrained from the HP separators. This option was
judged the optimum because of the minimal downtime
required and the high cost of deferred production.
Major progress was accomplished during late 1994/early
1995. In addition to installation of the cyclone vessel and
HP gas coolers, the BGC and oil pipeline pumps were
rewhecied to provide higher discharge pressures and flow
rates. The piping and heat exchanger of the final stage of
compression of the BGC were revised for higher discharge
pressures. Spare pipeline and LACT charge pumps were
ordered since standby pumps in these services had been
pressed into continuous sewice, Aback pressure valve
was added on the HP separators, FGC Natural Gas
Liquids (NGLs) were piped to the flare scrubber to
minimize recycle load on this compressor.
Another early problem involved higher than predicted
flash gas generated in liquid dump lines. This two phase
flow through the piping reduced the available pressure
drop for the dump valves. Also, where chokes were
installed downstream of level control valves to minimize
the pressure drop across the valve, the two phase flow was
limiting the flow across the choke. The chokes were
removed from the dump lines from HP and 1P separators
to increase flow capacity. Larger dump valves were
installed on the FWKO and BOT, Also. a second dump
line from the BOT to the dry oil tank allowed the Treater
pressure to be lowered, thus reducing the amount of gas
flashing off at the dry oil tank and reducing the back
pressure on the level control valves. High flash gas rates
had greatly exceeded the capacity of the first stage FGC,
Several operational changes also improved facility
performance, The most difficult well was diverted from
the HP to 1P separator. The operating pressure of the high
pressure ~stem was increased from approximately 1500 to
1800 psig. Flow from the wells was split between the HP
Oil Separator and the HP gas Separator, rather than being
segregated into one vessel or the other. Trials of antifoam
chemicals in the high pressure systems and friction
reducing chemicals in the oil export pipeline had some
137
3
success. Finally, fluid samples were obtained from several
wells. The results from the laboratory analyses and PVT
studies were incor-pxated into the process simulation
model which then provided satisfactory agreement with
actual Auger operations.
As a result of the stage 1 debottlenecking work, Augers
production rates were increased to 62,000 BBL/D and
125 MMSCFD. Production was limited by the amount of
liquids in the gas pipeline, foaming in the HI? Separators,
and by TEG contactor capacity. Attempts to reduce liquid
drop out in the gas pipeline by changing facility and
pipeline operating conditions, varying pigging frequency,
and use of JT recycle from HP to 1P systems have achieved
only limited improvement.
Stage 2 Debottlenecking Work - Late 1995
(Figure 3)
In September 1995, the gas pipeline company had a
curtailment scheduled that precipitated a complete
production shutdown on Auger, during which several new
pieces of equipment were installed, A new vertical high
pressure gas separator which incorporated a vane type
inlet spreader, internal spray nozzles for foam abatement
and outlet gas vane type mist extractor, and a new
coalescing filter vessel were installed. Other late 1995
debottlenecking work included a 20 pipeline tie-into the
Auger oil pipeline to Eugene Island 331, a new manifold
header for the HP vertical separator and installation of a
vent boom and vent scrubber for the new separator PSVS.
A new glycol contactor was installed and circulation
capacity was increased from 750 to 1200 GPH with flow
split between the two contractors, A larger glycol/glycol
heat exchanger was installed and higher capacity packing
was installed in the glycol still and reboiler sparger
columns, A permanent Vapor Recovery Unit (VW) was
installed to supplement the existing FGC, but tie-ins were
not completed.
By mid 1995, the resewoir engineers had determined that
the Waterflood System would not be needed. If it could be
removed, it would provide the necessary weight savings to
allow further expansion of the production facilities.
As a result of these equipment additions, flow rates
increased to 73,000 BOPD and 154 MMSCFD; but the HP
Vertical Separator did not perform up to its design rate of
170 MMSCFD. The problem appeared to be inefllcient
separation of oil and gas, which manifested itself as
increased gas rates at the 1P separator and carryover of oil
into the outlet gas stream.
Stage 3 Debottlenecking Work -1996 (Figure 4)
In April 1996, a major shutdown was executed by the gas
transportation company to increase their liquids handling
capacity. During this shutdown, vortex tube inlet devices
were installed in the HP vertical separator and several gas
 4 THE AUGERPLATFORM:DEBOTTLENECKINGAND EXPANSION
OF FLUID HANDLING FACILITIES
pipeline control valves were re-trimmed. Also during the
shutdown, miscellaneous tie-ins were made in preparation
for fhrther expansion and to finalize the VRU installation.
After these changes were made, Auger rates climbed to
over 73,000 BBL/D and 163 MMSCFD. Effectiveness of
the VRU, however, was hampered by recycling of
compressor generated NGLs.
Atler installation of the vortex tubes, the need for
injection of defoamer chemicals decreased significantly
and the separator etliciency improved, specifically in
reducing the amount of gas carry-under in the oil fedng
1P system.
Conversion of the existing filter separator to a coalescer
vessel and revision of tower internals in the original TEG
contactor are planned for later in 1996. An upgrade to the
produced water handling system will also be required since
water production is anticipated by the end of 1996.
A continuing problem that has not yet been resolved is
the excessive condensation of hydrocarbon liquids in
compressor interstate coolers. Condensed liquids are
dumped to lower pressure vessels where they re-flash and
the vapors are then recompressed. Considerable
compressor capacity is required to handle the recycle
vapors,
Peak rates are expected to reach 75,000 BOPD and
165 MMSCFD.
Future Expansion Plans (Figure 5)
Work has begun to firther increase the capacity of
Auger, possibly to 100,000 BBL/D of dry oil or
140,000 BBL/D of wet oil and 300-400 MMSCFD of gas.
New facilities on Auger will include a 14 riser, a new dry
oil train, a fourth pipeline pump and LACT train, a new
parallel BGC, some flare train work, and additional glycol
system capacity. These expansions are made possible by
the weight savings from demolition of the Waterflood
System. Some type of condensate weathering or
stabilization may be provided to reduce compressor NGL
recycle. The existing 12 oil pipeline will be converted to
gas service and a new 16 oil pipeline will be installed
from Auger to transportation infrastructure in shallower
water,
Case History For Future Improvements
When undertaking a new facility design, the best fluid
characterization is usually used, but relying on that to be
exact can give too tight of a design for the facilities. Some
flexibility should be considered if actual production data
does not exactly match the design conditions. Also, for
specific component designs, some sort of sensitivity
analysis may be beneficial. A case in point is the Auger
gas pipeline. The gas rates have been somewhat higher,
but the real surprise has been the liquids generated in the
pipeline. Small differences in the concentration of mid-
138
SPE 36S84
Ievel hydrocarbons, (c4, c5, c6, etc.), in the gas stream can
give huge differences in the volumes of liquids generated
in the gas pipeline. Some sensitivity analysis might have
dictated a more flexible design for the liquids handling
system going toward shore.
Another learning woutd be to allow for design engineers
to plan for facility expansion from the start. This would
include flanged break out spool piping to minimize on-site
welding and downtime. Also, if in the original design,
when staff time and resources were more available, higher
rates were anticipated, accounted for and documented,
then the job of the debottlenecking engineer would be
made greatly easier. Various contingencies could be
documented and preliminary expansion designs
completed. This would mean that debotttenecklng efforts
could begin directly in execution, rather than with design.
Many facility project engineers have developed their
skills by working major projects and facility designs. In
these designs of new production facilities, several key
parameters are understood and fixed. Generally a design
basis is developed, leading to a cost estimate and finally a
schedule is developed. All three of these components are
then largely fixed and the engineers can execute the
project with these basic boundary conditions unchanged,
An engineers job is to hold the cost, meet the schedule,
and build the agreed design.
In the case of debottlenecking an operating facility, all of
the normat constraints are turned upside down. The
schedule is usually ASAP, and may change based upon
plant turnarounds and shutdowns dictated by outside
forces. Schedules, therefore, are always changing, trying
to take advantage of every opportunity for acceleration.
The capital cost, while not unlimited, is usually minor
compared to the profit potential provided by either
minimizing shut in time or maximizing production rates
for a major production facility. Finally, the design basis is
not fixed because new data and production information
continues to come to light. Your debottlenecking design
must be flexible to account for changes in production and
new information, It also must be flexible to take
advantage of other opportunities for installation during
unexpected shutdowns.
Jn short, everything you learned building the project the
first time is out the window for the debottlenecking effort.
All your normal constraints are backwards.
Finally, when working with an operating facility, it is
vitally important to communicate with the field operations
staff. The differences in location and rotating schedules of
the field people make this a huge time burden, but a
necessary one. Any change or addition that the engineer
wants to make will have to be operated by the field
personnel. If they are not on board with the designs from
the beginning, your odds of success are limited. Atso,
most engineers dont want to admit this, but the operations
 SPE 36594 T. R, JUDD AND C. B. WALLACE 5

folks can have some very good ideas for process

improvements. These ticld generated ideas should be
seriously considered along }vith those generated from the
ivory towers.
Tables

Table 1- Auger TLP Production Facility - Production

Rates

Production Facility Oil Rate Gas Rate

Conllguration MMBOPD MMSCFD 1
Original Design 40 100
Initial Configuration 55 105
Stage 1 Debottlenecking 62 125
I Stage 2 Debottlenecking I 73 I 154 1
Stage 3 Debottlenecking I 75 ) 165
Auger Expansion 100 I 300

Fi~res

Fig. 1- Auger Production Fat. - Original Installation

Fig. 2- Auger Production Fat. - Stage 1 Debottlenecking
Fig. 3- Auger Production Fat. - Stage 2 Debottlenecking
Fig. 4- Auger Production Fat, - Stage 3 Debottlenecking
Fig. 5- Auger Production Fat. - Facility Expansion
Fig, 6- Auger Production His[ory

Nomenclature

B(X - Booster Gas Compressor

BOT - Bulk Oil Treater
FGC - Flash Gas Compressor
FWKO - Free Water Knock Out
HP - High Pressure
1P - Intermediate Pressure
NGL - Natural Gas Liquid
TEG - Tri-ethylene Glycol
VRU - Vapor Recovc~ Unit

139
 THE AUGER PIATFORM: DEBOTTLENECKING AND EXPANSION SPE 365S4
OF FLUID HANDLING FACILITIES

Figure 1
AugerProductionFacilities
Oripinal Installation
Design Oil Rate = 40 MBOPD Max Oil Rate =
Design Gas Rate . 100 MMSCFD Max Gas Rate = us

44 + HPGas
Filter
TEG
Contactor
GAS

GAS
WELLS
f
HP Gas r
Sep ~ EXPORT

4
I A
+ ~ BGC2 Dry Oil
4b .

b
OIL t A
WELLS
HP Oil
%

v IPSep

I
BGC = Booster Gas Compressor Bulk Oil
FGC = Flash Gas Compressor Treater

+ D

Figure 2

AugerProductionFacilities
StagelDebottlenecking Max Oil Rate = Q
Max Gas Rate m
Cyclone
Fin-Fan GAS
TEG
Contactor
EXPORT

HP Gas
Sep

+ Dry Oil

4+

* FGC
I 4
A
t
HP oil
Sep
Most
Oil ~
Wells 4 IP Sep

as Wells Sh ut-m 1
~] m
BGC = Booster Gas Compressor
FGC = Flash Gas Compressor Dry Oil Tank]
I
I and Export 1
140
SPE 3s5s4 T. R. JUDD AND C. B. WALLACE

Figure 3

AugerProductionFacilities
Stape2Debottlenecking Max Oil Rate = 73
Max Gas Rate = m

Dry Oil

FGC
I
b

,
+ + W Sep I I
[
CGas Wells Shut-in>

BGC = Booster Gas Compressor

FGC = Flash Gas Compressor Dry Oil Tank
I and Export
Fimre 4
AugerProductionFacilities Max Oil Rate = U
StaA3Debottlenecking Max Gas Rate = -l&5

7
~GAS
EXPORT

n Dry Oil
Tank
Vapors

BGC = Booster Gas Compressor

FGC = Flash Gas Compressor Dry Oil Tank
and Export
141
 THE AUGER PIATFORM: DEBOTTLENECKING AND EXPANSION SPE 365W
OF FLUID HANDLING FACILITIES

Figure 5

AugerProductionFacilities Max Oil Rate. ~

Max Gas Rate = ~
fhwefixDansion
TEG GAS

r-if
HP Contactor - EXPORT
Cyclone
- vat No. 2
,% HP Gas TEG
Contactor GAS
%m - EXr--
ruKl

I.!RJf-p+-
as 5
10 *
I~-%
II ~1-1- - ---- t 14
t ].e..,wol;
A RegenSys I
, . BGC1
.
VRL[J b n.
ury WI
nll 1

Tank
mm. 7 &--
Vapors
lwelk~ I---HI I J-J
I
c-ii
l-l
pwlk I
n 4--IFT
HP Dry
OiLSep
I
1P Dry
OiBep
t

1
i D~OilTank
New Lact & and Export
I BGC = Booster Gas Compressor
[ P/Ilunlps I FGC = Flash Gas Compressor

Figure 6

AugerProductionHistory
180
1
Stage 3 ~
160
1

Debottlenecking Stage 2 ~
l+- stage 1 +
140

120

100

80

60

40

20

1995 1996-
142