copy of iemr-cest-oil production

7/28/2019 Copy of IEMR-CEST-Oil Production

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Oil and Gas Production


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Oil and Gas Industry Overview (UPSTREAM)

Source: Methane to Markets, Oil & Gas Industry Overview


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Production Flow Diagram

Source: Oil & Gas Production Handbook , ABB


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Separation


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WELL FLUIDS & WELL CLASSIFICATION

Wells are generally classified according to the type of fluid they produce in

the greatest quantity.

CLASS OF WELLFLUIDS IN

RESERVOIR

FLUIDS IN FLOW

LINE

PROCESSING STEPS

WHICH MAY BE

REQUIRED

DRY GASGAS, POSSIBLY

WATER

GAS, POSSIBLY

WATER

SEPARATION, GAS

DEHYDRATION

GAS CONDENSATEGAS, POSSIBLY

WATER

GAS CONDENSATE,

POSSIBLY WATER

SEPARATION, GAS &

CONDENSATE

DEHYDRATION

CRUDE OIL

CRUDE OIL,

POSSIBLY GAS

POSSIBLY WATER

CRUDE OIL,

POSSIBLY GAS,

POSSIBLY WATER

SEPARATION, GAS

DEHYDRATION

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


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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.



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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.



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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 re-

entrainment of one into the other takes place.



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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



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TYPES OF SEPARATOR

GAS / LIQUID SEPARATORS- Vertical



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TYPES OF SEPARATOR

GAS / LIQUID SEPARATORS- Horizontal



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TYPES OF SEPARATOR

GAS / LIQUID SEPARATORS- Tangential or Cyclone



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TYPES OF SEPARATOR

LIQUID / LIQUID SEPARATORS- Coalescer



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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


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Gas Treatment and Compression


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HEAT EXCHANGER

Heat transferis 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


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Modes of Heat Transfer

Conduction

Convection

Radiation

Source: Wikipedia


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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
http://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdf


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


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


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Tube Bundle

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


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Baffle Arrangement



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


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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 tothe 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
http://www.engineersedge.com/heat_exchanger/plate.htmhttp://www.engineersedge.com/heat_exchanger/plate.htm


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


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Source: Heat Exchangers, Types and Applications

Cairo University, Faculty of Engineering, Chemical Engineering Department


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SCRUBBERS & REBOILERS

Source: Oil and Gas Production Handbook, ABB


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COMPRESSORS

A gas compressoris 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
http://en.wikipedia.org/wiki/Gas_compressorhttp://en.wikipedia.org/wiki/Gas_compressor


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TYPES OF COMPRESSORS

PARAMETERS RECIPROCATING

COMPRESSORS

SCREW

COMPRESSORS

AXIAL BLADE

COMPRESSORS

CENTRIFUGAL

COMPRESSORS

Build A piston and cylinderdesign with 2-2

cylinders

Two counterrotating screws

with matching

profiles provide

positive

displacement and a

wide operating

range.

Axial blade and fintype Compressors

with up to 15

wheels provide

high volumes at

relatively low

pressure

differential

(discharge pressure

3-5 times inlet

pressure)

Centrifugalcompressors

with 3-10 radial

wheels, Pressure

differential up to 10.

Power (MW) 30 MW up to several MW Upto 80 MW

Synchronous Speed

(rpm)

500-800 3000/3600 5000-8000 6000 20000

(highest

for small size)

Pressure 5 MPa 2.5 MPA (25 bars) Upto 50 bars

Used for Lower capacity gas

compression and high

reservoir pressure gas

injection

Typical use is

natural gas

gathering.

Air compressors

and cooling

compression in

LNG plants

Larger oil and gas

installations



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Reciprocating Compressor Screw Compressors


Axial Blade CompressorsCentrifugal Compressors


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Performance Control

The object of the compressor performance controlis to keep the operating point

close to the optimal set pointwithout violating the constraints, by means ofcontrol 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



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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 bothand 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


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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


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Methanol : Injected in flow lines to prevent hydrates formation and corrosion

Hydrates are crystalline compounds that form in water crystalline structures as afunction of composition, temperature and pressure.

Hydrates might form and freeze forming hydrate ice, that may damage pipes andequipments.

Hydrates prediction model software can be used to determine when there is a risk ofhydrate 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 inpipelines.

Sources : Oil & gas handbook production ABB, Wikipedia


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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 areused, such as cryogenic and membranes.



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Oil & Gas Storage, Metering and

Export


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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.


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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; ABBhttp://www.standard.no/PageFiles/1224/I-SR-104r1.pdf


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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


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Metering System


htt ://instrumenttoolbox.blo s ot.com/2011/05/how-to-construct-instrument.html


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Gas metering

Gas metering is similar, but instead, analysers will measure

hydrocarbon content and energy value (MJ/scm or BTU, Kcal/scf) aswell 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.



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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.

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