Lectures 1

Y-4
Surface Production
Facilities
Dr. Atef Abdelhady
SPF Mission

Key words:
process engineering, dehydration, oil, NGL,
LPG and LNG, minor components,
distillation, contaminant removal, storage and
evacuation, storage tanks, pipelines, subsea
production system,
distribution network and terminals.
SPF = surface production facilities
Production technology topic

















































Oil and gas processing Oil and gas processing


Objectives of SPF
To separate natural gas,
condensate, or oil and water
from a gas producing well and
condition these fluids for sales
or disposal
Processing Plants
Recovery of condensable natural
gas liquids from conventional gas
(i.e, butane, propane, etc.)
Pumps, turbines, compressors,
dehydrators, flare etc.
POTENTIAL GHG EMISSIONS
Tank emissions should be minimal
Engine Exhaust CO2
Heater Exhaust CO2
Dehydration None if dessicant system;
Methane & CO
2
if glycol.
Pipeline Leaks Methane and CO2
Flare CO
2

Compression
Liquids Recovery
Dehydration
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Treating Plants
Removal of entrained
CO2 from natural gas
Compressors,
dehydrators, heaters,
etc.
POTENTIAL GHG EMISSIONS
Direct CO2 venting CO2
Tank emissions should be minimal
Engine Exhaust CO2
Heater Exhaust CO2
Pigging Activities Methane and CO2
Compression

CO2 Removal
Dehydration
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To Distribution Line
Natural Gas Treating Plant


What is Gas Processing ?

Separation of oil and gas and removal of
impurities and NGLs from Natural gas
What is gas treatment ?

Removal of impurities, condensate, H2S and
NGLs from Natural Gas.


What is the petroleum value chain ?

The petroleum value chain is divided into
three parts :-
1- Upstream
2- Midstream
3- Downstream


List petroleum products we use every day?

1- LNG, C1,C2
2- LPG, C3,C4
3- Sales gas, C1,2,3,4
4- Gasoline, C5



What is Natural gas processing plant ?

A NATURAL GAS PROCESSING PLANT is a
facility designed to clean raw NG BY
SEPARATING IMPURITIES and non- methane
hydrocarbons and fluids to produce what is
known as pipeline quality dry natural gas.
A gas processing plant is also used to recover
natural gas liquids, condensate, gasoline, LPG
AND sometimes other substance such as CO2,
H2S, Sulfur.
Introduction

What is the job or function of a production facility?
Is to separate the well stream into three components,
typically called phases (oil, gas, and water), and
process these phases into some marketable product(s)
or dispose of them in an environmentally acceptable
manner. In mechanical devices called separators, gas
is flashed from the liquids and free water is separated
from the oil. These steps remove enough light
hydrocarbons to produce a table crude oil with the
volatility (vapor pressure) to meet sales criteria.
Production Facilities Issues
There are number of issues should be
considered surface production facilities:-
1- How to gather well fluids?
2- How to treat produced fluid?
3- Where to treat produced fluid?
4- How to transport products
5- How to store products?
Hydrocarbons
from reservoir
to SPF


Surface Production Facilities
Location Types

1- Onshore or Land
2- Offshore
3- Subsea

Production Facilities
1- Land production facilities
a- Well sites, the first function is to accommodate drilling
operations, and also a well site must be designed to
allow access for future operation and maintenance
activity.
b- Gathering stations
The term gathering station may describe anything
from a very simple gathering and pumping station to a
complex processing centre in which produced fluids
are treated and separated into gas, NGLs, and
stabilized crude.

Offshore platforms
Offshore platforms can be split into two categories:-
1- Fixed production platforms.
2- Floating production platforms
Fixed platforms are generally classified by their
mechanical construction to four types:-
A- Steel jacket platforms
B- Gravity- based platforms
C- Tension leg platforms, TLPs
D- Minimum facility systems
Production Facilities
2- Offshore production facilities
The functions of offshore production facilities are:-
1- Hydrocarbons have to be collected.
2- Processing and transportation .
Design and layout of the offshore facilities are very
different from those on land for the following
reasons:-

Production Facilities
1- A platform has to be installed above sea level
before drilling and process facilities
2- There are no utilities offshore such as light,
water, power, and living for manpower have to
installed to support operations.
3- Weight and space restrictions.

Offshore platforms
Floating platforms can also be categorized into
three main types:-
1- Semi-submersible vessels
2- SHIP-shaped monohull vessels such as
floating production, storage and offloading
( FPSO).
3- spar platforms
Subsea production systems
Subsea production systems are an alternative
development option for an offshore field. They
are a very cost effective means for small field
which are close to existing production platform
and pipelines. Subsea system would consist of
cluster of subsea X-TREES positioned on seabed
with produced fluids piped to the host facility.
Control of subsea facilities is maintained from
the host facility via control umbilical's and
subsea control modules
Subsea production systems
Subsea production systems create large savings in
manpower's as they are unmanned facilities.
The most basic subsea satellite is a single subsea
wellhead with subsea tree, connected to a production
facility by a series of pipelines and umbilical's.
A CONTROL MODULE FIXED ON THE SUBSEA TREE, allows
the production platform to remotely operate the
subsea facility via valves and chokes



Production Facilities
C- Evacuation and storage
Once oil and gas have been processed the
products have to be transported or evacuated
from the site. Stabilized crude is normally
stored in two types of oil storage tanks are
common used:-
1- Fixed roof tanks
2- Floating roof tanks
Why it is difficult to classify Production
Facility by types ?
Because they differ due to:-
1-Production rates
2- Fluid properties
3-Sale requirements
4-Disposal requirements,
5-location

Production Operations
Gas, oil, and/or
condensate production
Unloading wellbore
fluids
Crude Oil and Produced
Water Transport
Artificial Lift
How Making the Equipment Work?
The main items of process equipment have automatic
instrumentation that :-
1-Controls the pressure and/or liquid level and
sometimes temperature within the equipment. Figure
below shows a typical pressure controller and control
valve.
2- The controller is a device that sends a signal to the
actuator, which opens and closes the control valve to
control pressure.
3- Also another figure shows level controller to adjust
level inside separator.



What are Twelve Steps?
To Engineering Safe Oil and Gas
surface production facilities?
1- Design-Standards Policy
2- Site layout for safety
3- Design vessels and piping properly
4- Select the proper tank
5- Proper pressure vessel
6- Specifying the rotating equipment
7- Choose Relief safety system
8- Identify Control system
9- Electrical area classification
10- Personnel safety
11- Perform Process hazard analysis
12- Procedures for start up and commissioning



Summary

The purpose of the surface facilities is to deliver saleable
hydrocarbons from the wellhead to the customer, on time,
to specification, in a safe and environmentally acceptable
manner.
The main functions of the surface facilities are

Gathering (e.g. mani folding together producing wells)
Separation (e.g. gas from liquid, water from oil, sand from liquid)
Transport (e.g. from platform to terminal in a pipeline)
Storage (e.g. oil tanks to supply production to a tanker)