2.surface facilities

SURFACE FACILITIES PAB 2073

Mrs Putri Nurizatulshira Buang

Source: E&P Core Programme INSTEPTopic OutlineIntroductionProduction facilities layoutLand based production facilitiesOffshore based production facilitiesOffshore Topside Facilities

Source: E&P Core Programme INSTEP

Source: E&P Core Programme INSTEPINTRODUCTIONThe mixture of oil, gas, water and undesirable substances produced at wellhead has to be separated and treated for export and disposalThe processing facilities has to cope with changing produced volumes over field life timeBadly designed process can cause reduced throughput and expensive plant/platform modifications after start-upOver-capacity or unnecessary process flexibility can also be very costly


Source: E&P Core Programme INSTEPType of processing required is dependent upon fluid composition at wellhead But equipment employed is significantly influenced by location i.e. on land or offshore; in tropical or arctic environmentsProcessed fluids, gas must meet transport or storage specifications and legal limit of emission to environment for e.g. flare of gas and produced water qualityUpgrading of facilities to reduce emissions is much more costly once production


Source: E&P Core Programme INSTEPEngineering design should be focused on adding greatest value to the product at least cost, while working under the framework of health, safety and environmental policy


Source: E&P Core Programme INSTEPProduction Facilities LayoutOnce a process scheme is defined, the layout of the equipment and plant is determined by transportation considerations and by surface environmentImportant considerations for facilities on land and off shore includes:How to gather well fluidsHow and where to treat produced fluidHow to evacuate or store products


Source: E&P Core Programme INSTEPLand based Production FacilitiesIf the land surface above a reservoir is relatively flat, cheaper to drill and maintain a vertical wellIn unpopulated areas common to find pattern of wellheads at surface closely reflects pattern which wells penetrate reservoirIn areas with housing and environmental and topography concerns, wells are drilled in clusters as close as possible to surface location of the reservoir


Source: E&P Core Programme INSTEPWellsitesWellsite is to accommodate drilling operationsDesigned to allow future operations and maintenanceProvide containment on event of accidental emissionProduction from wellhead/wellhead manifold is routed by pipeline to gathering station often without treatmentIf well produce naturally or with downhole pump, there is only little equipment on site during normal operations


Source: E&P Core Programme INSTEP2. Gathering stationsCan be a simple gather and pump station to a complex processing centreIf several widely spaced fields are feed into a single gathering and treatment centre, it is common to perform primary separation of gas, oil (and water)


Source: E&P Core Programme INSTEPSimple Field stationSlug catcher, temporary storage tanks and pumps to pump the separated fluids to main gathering and treatment centre

Slug CatcherTankProduced FluidsOilGas


Source: E&P Core Programme INSTEPComplex gathering stationFacilities to separate produced fluids, stabilise crude for storage, dehydrate and treat sales gas, and treat waste products for disposal

Gathering StationTank storageSales Gas PipelineNGLSingle wellhead or wellhead manifold


Source: E&P Core Programme INSTEP3. Evacuation and storageStabilised crude normally stored at tank farms at distribution terminal At distribution terminal, crude is stored prior to further pipeline distribution or loading for shipment by sea Sales gas piped directly into national gas distribution network (example)NGL products stored locally in pressurised tanks and then distributed by road or sea shipment directly from gathering station


Source: E&P Core Programme INSTEPFor oil, it is stored in storage tanks2 types of oil storage tanks, fixed roof tanks and floating roof tanksStorage tanks should always be closely surrounded by bund walls to contain crude in event of spillage incident and provide protected access to fireman Drainage systems inside bund wall should only be open with monitoring to avoid accidental release of hydrocarbon liquids


Source: E&P Core Programme INSTEPOil tanks within bund walls


Source: E&P Core Programme INSTEPOffshore based Production FacilitiesDesign and layout of offshore production facilities are very different from land based facilities because:A platform has to be installed above sea level before drilling can take placeUtilities such as light, water, power and living quarters have to be installed to support operationsRestrictions on weight and space requires alternative storage methods


Source: E&P Core Programme INSTEPOffshore PlatformsPlatforms are classified by their mechanical constructionJacket based platformsGravity based platformsTension leg platformsFloating production platforms


Source: E&P Core Programme INSTEP1. Jacket Based PlatformsSubstructure made from steelMost common type of platformEmployed on wide range of sea conditionUsed in water depth up to 150 mJacket is made of large, tubular, welded steel pipesPinned to sea floor using steel piles 1-2 m thick as deep as 100 mJackets weigh up to 20,000 tonnes


Source: E&P Core Programme INSTEPConstruction of steel jacket platformsJacket fabricated onshore and then floated out horizontally on barge and set upright on locationOnce in position, jacket is pinned to sea floor with steel pilesPrefabricated modules to place processing, drilling, power and utilities equipment are installed by lift barges on to top of jacketThe whole assembly is connected and tested (commission)


Source: E&P Core Programme INSTEP2. Gravity Based PlatformsSubstructure made from concrete or steelRely on weight to secure them to the seabed i.e. no need pilingHave huge ballast tanks surrounding hollow concrete legsLegs of platform can be used as settling tanks/temporary storage facilities Weighs more than 200,000 tonnes

Ballast tanksHollow legs


Source: E&P Core Programme INSTEP3. Tension Leg PlatformsTLP is like a semi-submersible rig tethered to seabed by jointed legs kept in tensionTension is maintained by pulling floating platform down into seaLegs secured to anchor points installed on seabedMainly used in deep water


Source: E&P Core Programme INSTEP4. Floating Production PlatformsCommon for development of small fields which cannot support cost of a permanent platformFloaters as substructureTankers/ships/Semi-submersible rigs converted to production platforms such as Floating, Production, Storage, Offloading vessels (FPSO)s or FSOsCan move from field to field as reserves depletedDeepwater also uses floating structures such as SPAR


Other types of platformMOPUHybrid platform - jacket platform with concrete foundationMonoshaft tower with pile foundationGuyed towerConcrete articulated towerCompliant platformsSPAR



Source: E&P Core Programme INSTEPEvacuated by pipeline or (oil ) tankers 1. Pipeline Pipeline is most common especially when dealing with large volumes of hydrocarbonsFailure to design a pipeline which can withstand operating conditions over field life time can lead to costly deferred oil production in cases of pipeline leak or bottleneck due to wax accumulation

Offshore Evacuation Systems


Source: E&P Core Programme INSTEPLong pipes are installed using lay barge where welded connections are made one at a time as pipe is lowered into seaPipelines buried as protection Shorter pipelines can be constructed onshore and then towed offshore



Towing a pipeline offshore


Source: E&P Core Programme INSTEPOffshore loading to tankersUsed in seabed areas where pipelines not safe to install or projects where not economic to use pipelinesOil is evacuated from processing facility directly to tankerLoading carried out through Single Buoy Mooring (SBM)


Source: E&P Core Programme INSTEPTanker is tied up and may rotate around SBMOne or two tankers may be used depending on storage capacity of production platformSBM has no storage facility but in some areas (DW) has been developed with storage facilities such as Spar type storage terminals


Source: E&P Core Programme INSTEPTanker Storage and Export


Source: E&P Core Programme INSTEPSingle Buoy Mooring


Offshore Topside Facilities


Offshore topside structure provides facilities to perform the primary function of processing and storage of hydrocarbon fluids received from wellhead prior to evacuation to onshoreBesides that, offshore topside should be able to provide other support such as power generation, fire protection system, living accommodation for workers


Primary Operation of Surface FacilitiesSeparationWellsReservoirOil treatmentOILGASWATERWater treatmentDehydrationStorage/exportdisposalWater injectionGas salesGas injectionGas liftFuelFlare


Functions on offshore platforms:Well controlSupport for well workover equipmentSeparation of oil, gas, waterTreatment of oil, gas, waterSupport for pumps, compressorsPower generationAccommodation


Topside structure concepts:Single integrated deckSplit deck in 2 four-legged unitsIntegrated deck with living quarter moduleModularised structure consists of series of modules


UtilitiesLiving QuartersPower GenerationWater treatmentWellheadProductionCompressor


Major equipments/systems Wellhead/X-mas treePiping/flowlinesValvesSeparatorGas handling systemWater treatmentPumpsCompressorsInjection systemsPower generator

CraneUtility systemInstrument & service airStarting airPortable waterFuel gasDrainage Fire water Chemical injectionFire protection systemBrucker


2.surface facilities

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ep core programme instepsource

ep core programme instepland

ep core programme instep2

surface facilities pab

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flare of gas

produced fluidhow

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