sessiion 2 upstream process-dvs

8/12/2019 Sessiion 2 Upstream Process-DVS

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Title : UPSTREAM-PROCESS

Faculty: D.V.SWAMINATHAN

Date: 30.10.2006

Venue: Auditorium, 4th floor, EPC Block

CALD Series II Technical

Offshore Upstream Oil & Gas Business Training Module

Objective of CALD: to update expertise in EPC

Organized by: E&C - HR


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INTRODUCTION TO OIL INDUSTRY-EXPLORATION PHASE

Exploration involves particularly collection and correlation of

geological sections over large areas.

A geologist maps a given area of interest. The mapping involves

plotting geological data on a map.

The rock sections over a large area is described and differentformations are plotted to show their distribution.

Types of maps

Plots of surface structuresThickness maps which illustrates thickness of various

formations

Lithological maps which shows variations in rock types.

Porosity maps showing variations in porosity


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EXPLORATION PHASE SURVEY VESSEL


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EXPLORATION PHASE

Above all identifying the source rock and reservoir rock, their

distribution and thickness.

Correlation of the above data provides a vital information of the

Structure

Stratigraphy

Thickness

The mapping is done with different types of surveys and loggingto establish the surface and sub-surface geology.


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DEVELOPMENTAL PHASE

Upon discovering the question is whether it is worth developing.

Number of wells are drilled called assessment wells or

delineation wells for collecting basic information.

During this process geological environment of hydrocarbonaccumulation is gained extensively. (e.g..)

Properties of reservoir fluids

PVT relation ships

Petro-physical properties of rocksWater Zones, Gas Zones

Core Samples to determine porosity and permeability

Likely In-place Oil reserves are determined


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RESERVOIR STRUCTURE-TYPICAL


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DRILLING UNITS-SIMPLIFIED


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A TYPICAL X-MASS TREE


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DRILLING, COMPLETION, PRODUCTION PHASE

Subsequent to the developmental phase once the commercial

viability is confirmed the wells are finally drilled.The wells are drilled and completion is achieved. Some wells

are drilled and capped to be completed later.

The wells are drilled by the drilling rigs.

The surface infrastructure to exploit and transport thehydrocarbons is planned and installed to begin the production

phase.

There could be different types of Offshore structures depending

on the water depth.

The structures/facilities above the surface of the sea level iscalled TOPSIDES.

The structures below the sea level to hold the TOPSIDES are

called JACKETS. (Applicable for FIXED TYPE

PLATFORMS).


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Phases in Offshore Oil & Gas Project

Pre-Bid Engineering & Bid Submission

Award of Contract

Detailed Engineering

Procurement

Fabrication

Load-out

Transportation

Installation

Pre-commn.

Commn.

Conceptual Study FEED- Front Engineering & Design Invitation for Bid


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OFFSHORE STRUCTURES

Platform Pipeline

Fixed

Platform

Floating

PlatformRigid Pipeline Flexible Pipeline

Drill ships Semi-Submersible Floating

Production

FSOFPSO

Steel Jacket

Structure

Concrete GravityStructure

Rigid Compliant

Guyed

TowerTension Leg Platform Spar

Jackup


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WELL HEAD PLATFORM


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PROCESS PLATFORM


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COMPRESSOR MODULE


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TOP SIDE FACILITIES UNMANNED PLATFORM

Well Heads

Flow Lines

Manifolds

Test Separators

Inlet 2 Phase Separators( At Some Installations)

Solid Handling System ( At Some Installations)

Launchers & Receivers

Gas Injection Manifolds

Water Injection Manifolds

Inert Gas Generation


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TOP SIDE FACILITIES UNMANNED PLATFORM

Chemical Injection Skids

Fire Water Pumps & Network

ESD/ F&G Detection and Suppression Systems

Closed & Open Drain Systems

Vent Systems

SWGR, Battery Room, Telemetry Units

Solar Power Panels & UPS

Emergency Generators

Pedestal Crane

Other Safety Systems


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TOP SIDE FACILITIES- PROCESS COMPLEX

Oil & Gas Receivers and Launchers

Manifolds

Crude Oil Heaters

Production Separators

Crude Oil Stabilizing Units( At Some Installations)

Produced Water Conditioning Unit

Chemical Injection Skids

Electro-Chlorinators

Water Injection System



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PROCESS FACILITIES-OFFSHORE

Gas Compression

Gas Dehydration

Metering & Distribution

Fuel Gas Conditioning Unit

Waste Heat Recovery System

Crude Oil Transfer Pumps

Produced Water Disposal

Sump Systems

Flare and Vent Systems


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PROCESS FACILITIES-OFFSHORE

Power Generation

SWGR, Battery Room, Control Room

Living Quarters

Work Shops, Storage Room, Laboratories

Pot Water Systems

Fire Water Pumps and Network

ESD/F &G Detection and Suppression Systems

Other Safety Systems

ATF Fuelling Systems (At some installations)

Pedestal Cranes


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SIMPLIFIED PROCESS FLOW DIAGRAM - OIL & GAS SEPARATION )

W

E

L

L

F

L

U

I

D

H PSEPARATOR

SURGE

TANK

L PSEPARATOR

HOT OIL

WELL

FLUID

HEATER

PRODUCED

WATER

CONDITIONER

OVER BOARD

HOT OIL

TRAIN

B

TRAIN A

OIL TO SHORE URAN

TERMINALTHREE MAIN OIL

PUMPS

TWO LP BOOSTERCOMPRESSORS

TWO GAS

DEHYDERATIONUNITS GAS TO SHORE

URAN TERMINAL

THREE PROCESS GAS

COMPRESSORS

OIL TO SBM

FROM

TRAIN B

TO LIFT GAS

TO FUEL GAS

CRUDE

OILHEATER

SUMP CASSION

PGC APGC C PGC B

FROMT

RAIN B

THREE COT

PUMPS


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QUALITY OF OIL & GAS DESPATCHED, AND PRODUCED

WATER (DISCHARGED OVERBOARD)

A. OIL DESPATCHED:

WATER CONTENT Sp Gr / API Gr

POUR POINT

~ 0.1 % ~ 0.8256 / 39.89 ~ 27 Deg C

B. GAS DESPATCHED:

DESIGN CRITERIA

4 - 7

MOISTURE CONTENT: ( Lb/ MMSCF OF DEHYDRATED GAS)

C. PRODUCED WATER-

OIL IN WATER PPM

DESIGN CRITERIA

< 25 PPM

GAS FROM COMPRESSORS


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PIC203

HP CONDENSATE

COALESCER

SEPARATOROVERHEAD

SCRUBBER

GAS-GLYCOL

CONTACTOR

LIFT

GAS

GAS-

GLYCOL

EXCHAN

GER

LEAN GLYCOL

RICH GLYCOL

HP FLARE

FT

PT

TO

PIC-

2030

PIC

2050

TO CLOSED

DRAIN TO

GLYCOL

STORAGE

TANK

FUEL GAS PCV

TO LP FLARE

GLYCOL

FLASH

VESSEL

ACTIVE CARBON

FILTER

GLYCOL FILTERS

FT

RICH

GLYCOL

TO EXCH

-ANGER

RICH

GLYCOL

ILT

LT

TIC

TT

PI

RICH GLYCOLFROM

CONTACTOR

TO FLASH

VESSEL

FROM

FILTERS

ILCV XSDV

RICH-LEAN

GLYCOL

EXCHANGERS

(A,B,C)

TICTT

REFLUX

CONDENSOR

GLYCOL

STILL

REBOIER

STORAGE

TANK

BOOSTER PUMPS

CIRCULATION

PUMPS

LEAN

GLYCOL

TO

CONT-

ACTOR

TCV

TO LP FLARE

TO URAN

HOT OIL SUPPLY

HOT OIL RETURN

GAS DEHYDRATION

SYSTEM- OVERVIEWSTRPPING GAS

GAS FROM COMPRESSORS


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HP CONDENSATE

COALESCERSEPARATOR

OVERHEAD

SCRUBBER

GAS-GLYCO

L

CONTACTO

R

GAS TO

URAN

GAS-

GLYCOL

EXCHANGER

RICH GLYCOL TO REFLUX CONDENSOR

HP FLARE

FT

PT

TOPIC-

2030

LEAN GLYCOL

XBDV

PIC2030

XBDV

LIFT GAS

CONTACTOR SECTION


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TIC

TT

PI

TO FLASH

VESSEL

FROM

FILTERS

ILCV XSDV

RICH-LEAN

GLYCOL

EXCHANGERS

(A,B,C)

TICTT

REFLUX

CONDENSOR

GLYCOL

STILL

REBOIER

BOOSTER PUMPSCIRCULATION

PUMPS

LEAN

GLYCOL

TCV

TO LP FLARE

RICH GLYCOL

FROM

CONTACTOR

STRIPPER

H

O

T

O

I

L

REBOILER SECTION

STORAGE TANK

STRIPPING GAS


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Facilities at Water Injection Platform

Water Processing & Injection

Sea water Lift Pump

Booster pumps

Main Injection pump

Coarse Filters

Fine Filters

Deoxy Towers

Vacuum Pumps

Chemical InjectionSkids

Utilities:

Building Module & HVAC

SWGR,Battery Room, Control Room, Work

Shop, Storage Room

Utility and Instrument Air

Fire Water Pump

Utility Generator

Water Maker

Sewage Treatment


ATF Fuelling

Chemistry Laboratory

Instrumentation Laboratory


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Future


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COMMON ISSUES DURING DESIGN


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Dont try to hide any error because you cant do it forever. Plants are

going to be constructed and hence design errors will come to surface.

Error identification & root cause analysis will help the Project towards

success. This has impact on the Brand Equity & profitability of the

Company

Specification copied blindly from another project

Customers specification not thoroughly studied.

EPC contract not thoroughly studied.

Unverified inputs used not approved before final release


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Improper material selection.

Poor interface management within the disciplines

Interface templates for the respective disciplines not prepared

Interference between pipes, cables, structures.

Large variations in MTO requirement compared with actual.

Revisions not highlighted.

Comments Resolution Sheets not maintained

Deviations from specifications not tracked

Duplication of information on drawings


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ROLE OF A LEAD PROCESS ENGINEER

Review the Project Specifications related to the Process disciplinethoroughly.

Review the Process related deliverables required to be issued tothe COMPANY (Customer) as per contract.

Review the DCI (Document Control Index) generated by theEngineering Sub-Contractor and confirm the adequacy andcoverage of the deliverables.

Review and Comment on the deliverables issued by theEngineering Sub-Contractor before Issuing to COMPANY.

Ensure adherence to the Project Specifications.

Keep track of the documents issued to COMPANY and maintain

a Comment Resolution Sheet.Ensure that all the comments are incorporated in to thedeliverables before Re-issuing to COMPANY.

Keep track of all the deviations/changes related to process duringthe course of the project.


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TYPICAL PROCESS DELIVERABLES:

Simulation Reports- Heat & Mass Balance

PFD

P&ID

UFD

Equipment & Instrument Process Data Sheets

Equipment List

Utility Summary

Radiation & Dispersion Analysis

Hydrate Report


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PROCESS DELIVERABLES-Contd

Cause & Effect Matrix

SAFE Chart

Relief & Blow Down Report

Process Control & Shut Down PhilosophyVent & Drain Philosophy

Isolation Philosophy

HP Flare Study

Line Sizing CalculationsOperating Manual

Dynamic Simulation


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ROLE OF A PROCESS ENGINEER- INTERFACE

MANAGEMENT

Maintain an Interface Template

Ensure proper Interface with Piping, Instrumentation,

Mechanical, Safety disciplines.

Ensure that any change in the Process Data are appropriatelytransferred or shared with the related disciplines.

Ensure that the findings of Preliminary and the Final HAZOP

are incorporated in the respective process documents and sharedwith the related disciplines.

Participate in Safety studies along with the Lead Safety

Engineer


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PDMS MODELUNMANNED PLATFORM

PDMS SNAP SHOT UNMANNED PLATFORM


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PDMS SNAP SHOT-UNMANNED PLATFORM


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PDMS MODELUNMANNED PLATFORM

sessiion 2 upstream process-dvs

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