Surface Facilities Design

CHOPS Workshop

Surface Facilities Design Main topics

Surface Facilities design considerations
Process Scheme
Tanks Design
Sand Handling and Disposal
Surface Layout: Tanks, Lines, Power, Fiber
Optics, Flaring, etc.
Pads and Access Roads Specifications
Measuring Qo, Qw, Qg, Qs.
Tools and Equipment: Local Availability and
Canadian.

Surface Facilities Design Considerations

Objective:
To handle CHOPS pilot test wells fluids
To measure produced fluids, gas and sand.

Considerations:

Use only proven technology

Design to be as simple as possible
Foamy oil behavior considered (expansion factor: 5)
Facilities optimization is not intended at this stage
Facilities design and pump rates based on estimated
stable production of 400 BPD of EHO.
3

Process Scheme
DILUENT
INJECTION

VENT

(OPTIONAL)

GAS GATHERING

DEGASSING
BOOT

FLAME
ARRESTOR

DILUENT
INJECTION

PCP
PUMP

HEATER

DCO TRUNKLINE

WASH TANK

SURGE TANK

CASING
GAS
SAND TO CTF

CHOPS WELL

TEMPORARY
SAND STORAGE

VACUUM
TRUCK

Tank design

5.9 HR SLACK FOR PRODUCTION

ACCUMULATION
IN CONTINGENCIES

INTERFACE FOR 7HR

CONTACT TIME

WATER PAD

2 HR ACCUMULATED OIL
AND WATER
FOR PUMPING

ACCUMULATED SAND

TANKS:
- API 12F standard shop
fabricated tanks
- 750 barrels capacity
- 4.7 m x 7.3 m height
- Immersion Type Heater
- Duty: 286 KW
- Sampling points
DEGASSING BOOT:
- Wash tank with internal
Degassing boot.
- 0.6m diameter
- 3 internal plates.

DEAD SAND

OIL + WATER
DEAD VOLUME

WASH TANK

SURGE TANK

Sand Handling and Disposal

Sand separation at wash tank promoted by:
Fluid heating up to 80oC to reduce viscosity
Water bath to improve sand separation
7 hours residence time at normal liquid level.

Sand removal using an auger (screw)

Temporary sand storage and handling facility

Transportation using Super Vacuum Truck

Sand disposal is under investigation, possibility to mix

CHOPS sand with drilling cuttings at CTF for treatment
and disposal.
6

Surface layout: interconnection lines for

producer wells
Access road

Diluent pipeline

Existing
cluster
YC

DCO pipeline
Gas to Gas gathering system
Fiber Optic cable

Typical
CHOPS
well
pad

Power line

Surface layout: interconnection lines for

observation wells
Access road

Existing
cluster
YC

Fiber Optic cable

Power line ?

Typical
observation
well
pad

Pads and Access Roads Specifications

Pads:
Estimated Pad area: 70 m x 70 m
Area required for well drilling and servicing: 70m x 70m

Load capacity: 2.5 kg/cm2

Material type: Asphalt

Access Road:

Width: 6m
Load capacity: 2.5 kg/cm2
Material Type: Asphalt
Maximum slope: 7%
Radius of curvature: 60m
9

Preliminary Plot plan

(70m x 70m)

(70m x 70m)

Asphalt
(affected area)
Tanks &
Auxiliaries area

(70m x 90m)

200 m.

250 m.

None
affected
area

Wells

Pipe way

Access road

(70m x 70m)

(70m x 70m)
200 m.
250 m.
10

Surface layout: Tentative pad location

New pipe way &

cable route

New access road

NEW CHOP WELL PADS

11

Measuring Qo, Qw, Qg, Qs.

SP

Sampling point

Meter

VENT

GAS GATHERING

DILUENT
INJECTION

SP

HEATER

SP

WASH TANK

M
CASING
GAS
CHOPS WELL

SP

SURGE TANK

PCP
PUMP

SP
TEMPORARY
SAND STORAGE

DCO TRUNKLINE

Sand: wellhead
sampling
and sand
removed
from wash tank.
Water:
sampling at
wellhead
(BS&W).
Gas: casing gas
and
vent gas meters.

SAND TO CTF

VACUUM
TRUCK

Oil: mass flow

meter
at tank
discharge
12

Tools and Equipment: Local Availability and

Canadian.

Local or typical availability (none specialized):

Engineering
Tanks, pumps, piping and civil works
Electrical and instrumentation equipment.
Super Vacuum Trucks

Canadian (specialized)
Engineering consultancy
Auger design and fabrication

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Production / CHOPS Pilot Project-Surface Facilities Design / Luciano Da Costa

September 7th, 2005

Example of temporary
sand disposal facility

Vacuum truck
connection

Super Vacuum truck equipped with 8 hose.

Super vacuum truck

Discharge by gravity helped by
vibration mechanism
Volumetric capacity: 110 Bls.
Suck and transport liquids and solids.
Suction hose: 8 and 4
Suction capacity: 2500 m3/hr
Suction pressure: -0.91 barg

18

Example of Canadian tanks and auger

19

Estimated well production

Month
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Oil prod
(bbl)
Oil (bpd)
100
3000
200
6000
300
9000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000
400
12000

Oil cum
(bbl)
3000
9000
18000
30000
42000
54000
66000
78000
90000
102000
114000
126000
138000
150000
162000
174000
186000
198000
210000
222000
234000
246000
258000
270000

Sand cut
Sand
Sand
Sand cum
(% vol) prod (bbl) prod (m3)
(m3)
10
300
48
48
10
600
96
144
5
450
72
216
4
480
76.8
293
3
360
57.6
350
2
240
38.4
389
1
120
19.2
408
1
120
19.2
427
1
120
19.2
446
1
120
19.2
466
1
120
19.2
485
1
120
19.2
504
1
120
19.2
523
1
120
19.2
542
1
120
19.2
562
1
120
19.2
581
1
120
19.2
600
1
120
19.2
619
1
120
19.2
638
1
120
19.2
658
1
120
19.2
677
1
120
19.2
696
1
120
19.2
715
1
120
19.2
734

20

Process Scheme: option with 1 tank

DILUENT
INJECTION
(OPTIONAL)

VENT

DEGASSING
BOOT

FLAME
ARRESTOR

GAS GATHERING

DILUENT
INJECTION

PCP
PUMP
DCO TRUNKLINE

HEATER

CASING
GAS

SAND TO CTF

WASH TANK
CHOPS WELL

TEMPORARY
SAND STORAGE

VACUUM
TRUCK

21

Tanks Design: option with 1 tank

8HR SLACK FOR PRODUCTION

ACCUMULATION
IN CONTINGENCIES

Tank
-Atmospheric storage tank
-Size: 4.7m x 15.5m
(15-6 x 51)
-Shop fabricated

Degassing Boot
-Internal or external
-Diameter: 0.6m (24)
-3 internal plates

Vent

INTERFACE FOR 8 HR
CONTACT TIME

Electrical
heater

Degassing Boot

2 HR ACCUMULATED OIL
AND WATER
FOR PUMPING

Electrical
heater

WATER PAD
ACCUMULATED SAND
DEAD SAND

22