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MDPI/GIG OIL AND GAS TRAINING OIL AND GAS PROJECT MANAGEMENT PROCESS

MDPI/GIG OIL AND GAS TRAINING OIL AND GAS PROJECT MANAGEMENT PROCESS . Management Development and Goodwill International Group Productivity Institute Development Institute. Oil and Gas Production for Technicians. TABLE OF CONTENTS Objectives Introduction

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MDPI/GIG OIL AND GAS TRAINING OIL AND GAS PROJECT MANAGEMENT PROCESS

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  1. MDPI/GIG OIL AND GAS TRAINING OIL AND GAS PROJECT MANAGEMENT PROCESS Management Development and Goodwill International Group Productivity Institute Development Institute

  2. Oil and Gas Production for Technicians TABLE OF CONTENTS • Objectives • Introduction • Field Development and Production-Overview • Oil and Gas Production • Measuring Meters • Custody Transfer Point • Operation and Maintenance • Hazardous Area Classification and Work • Jobs and Opportunities Management Development and Petroleum Skills Productivity Institute Development Institute

  3. Oil and Gas Production for Technicians Objectives The module provides an introduction to the upstream sector of the petroleum industry by discussing the production of oil and gas. It assumes that exploratory drilling has been completed and it has been established that the field is commercially viable for production. Management Development and Petroleum Skills Productivity Institute Development Institute

  4. Oil and Gas Production for Technicians Introduction From the wellheads, reservoir fluids flow into the gathering system or production and test manifolds. In most cases the wellhead stream consists of a range of hydrocarbons, eg. methane, butane, propane, condensates and crude oil. Also included may be undesirable components like water, carbon dioxide, salts, sulphur, sand, etc. The purpose of the production facility, often called Gas Oil Separation Plant, is to clean and process the well fluids into marketable products of oil, natural gas or condensate. Management Development and Petroleum Skills Productivity Institute Development Institute

  5. Oil and Gas Production for Technicians Field Development and Production- Overview • After the size of field has been determined to be commercially viable, further wells are drilled. These wells are called ‘development’ or ‘production’ wells. • The number of wells required to exploit the hydrocarbon reservoir varies with the size of the reservoir and its geology. Large oilfields require many wells to be drilled, whereas smaller fields may require only a few wells, eg. ten or so. Management Development and Petroleum Skills Productivity Institute Development Institute

  6. Oil and Gas Production for Technicians Field Development and Production- Overview (Cont’d) • Recent technological developments, aimed at optimizing operations, include remotely operated subsea systems which remove the requirement for satellite platforms. This technology is also being used in deep water where platforms are unsuitable, and for marginal fields where platforms would be uneconomic. In these cases, floating systems, ships and semi-submersibles ‘service’ the subsea wells on a regular basis. Management Development and Petroleum Skills Productivity Institute Development Institute

  7. Oil and Gas Production for Technicians Subsea Completion Management Development and Petroleum Skills Productivity Institute Development Institute

  8. Oil and Gas Production for Technicians Field Development and Production- Overview (Cont’d) • Advances in horizontal drilling have enhanced directional drilling as a means of concentrating operations at one site and reducing the ‘footprint’ on land of production operations and the number of platforms offshore. Management Development and Petroleum Skills Productivity Institute Development Institute

  9. Oil and Gas Production for Technicians Directional Drilling Management Development and Petroleum Skills Productivity Institute Development Institute

  10. Oil and Gas Production for Technicians Field Development and Production- Overview (Cont’d) • The technology now enables access to reservoirs up to several kilometres from drill rigs. It also allows for more flexibility in selecting a drill site, especially where environmental concerns are raised. Management Development and Petroleum Skills Productivity Institute Development Institute

  11. Oil and Gas Production for Technicians Field Development and Production Overview (Cont’d) • As the wells are drilled they are prepared for production. The heavy drill pipe is replaced by a lighter weight tubing in the well. Sometimes one well may carry two or three strings of tubing, each one producing from different layers of reservoir rock. Management Development and Petroleum Skills Productivity Institute Development Institute

  12. Oil and Gas Production Oil and Gas Production for Technicians Management Development and Petroleum Skills Productivity Institute Development Institute Production is the most important stage of a well's life when the oil and gas are produced. • By this time the oil rigs and workover rigs used to drill and complete the well have moved off the wellbore, and the top is usually outfitted with a collection of valves called a production tree. Where the combination of controlling valves is more elaborate, the assembly is often called a Christmas Tree. • These valves regulate pressures, control flows and allow access to the wellbore in case further completion work is needed.

  13. Oil and Gas Production (Cont’d) Oil and Gas Production for Technicians Management Development and Petroleum Skills Productivity Institute Development Institute • From the outlet valve of the production tree, the flow can be connected to a distribution network of pipelines and tanks to supply the product to refineries, natural gas compressor stations, or oil export terminals. • Most new fields are initially free flowing with the underground pressures driving the liquids and gas up the well bore to the surface. As long as the pressure in the reservoir remains high enough, the production tree is all that is required to produce oil/gas from the well.

  14. Oil and Gas Production for Technicians Oil and Gas Production (Cont’d) • The rate of flow depends on a number of factors such as the properties of the reservoir rock, the underground pressures, the viscosity of the oil, and the oil/gas ratio. • Once the hydrocarbon reaches the surface, it is routed to the central production facility which gathers the hydrocarbon ready for processing. The production facility processes the hydrocarbon fluids and separates oil, gas and water. The oil is made free of dissolved gases before export. Management Development and Petroleum Skills Productivity Institute Development Institute

  15. Oil and Gas Production (Cont’d) Oil and Gas Production for Technicians • Similarly, the gas is stabilized and made free of liquids and unwanted components such as hydrogen sulphide and carbon dioxide. • Any water produced is treated before disposal. • The size and type of the oil and gas processing plant will depend on the nature of the reservoir, the volume and nature of produced fluids, and the export option selected. Management Development and Petroleum Skills Productivity Institute Development Institute

  16. Oil and Gas Production for Technicians Oil and Gas Production (Cont’d) • Primary Oil Recovery During the primary recovery stage, reservoir pressure is sufficient to force the oil to the surface. • Secondary Oil Recovery When natural reservoir pressure diminishes, secondary recovery methods that increase the natural reservoir pressure by an artificial drive are applied. Management Development and Petroleum Skills Productivity Institute Development Institute

  17. Oil and Gas Production for Technicians Oil and Gas Production (Cont’d) • Secondary Oil Recovery Available methods include beam pumps, electrical submersible pumps(ESPs), water injection, natural gas reinjection, hydraulic fracturing, acid treatment, gas lift which injects air, carbon dioxide, or some other gas into the bottom of an active well. On average, the recovery factor after primary and secondary oil recovery operations is between 35 and 45%. Management Development and Petroleum Skills Productivity Institute Development Institute

  18. Oil and Gas Production for Technicians Oil and Gas Production (Cont’d) Tertiary or Enhanced Oil Recovery (TEOR) Tertiary or enhanced oil recovery methods increase the mobility of the oil in order to increase extraction. These include: • Thermally enhanced oil recovery methods where the oil is heated, thus reducing its viscosity and making it easier to extract. • Steam injection, whereby steam is injected into the reservoir is the most common form of TEOR. • Surfactants (detergents) are sometimes injected into the well to alter the surface tension between the water and oil in the reservoir to enhance recovery. Management Development and Petroleum Skills Productivity Institute Development Institute

  19. Oil and Gas Production for Technicians Oil and Gas Production (Cont’d) Tertiary or Enhanced Oil Recovery (TEOR) • Carbon dioxide flooding is another method used to reduce viscosity to enhance recovery. • With microbial treatments, special blends of microbes are used to treat and break down the hydrocarbon chain in oil thus making the oil easy to recover. Tertiary recovery allows typically about an extra 5% to 15% of the reservoir's oil to be recovered Management Development and Petroleum Skills Productivity Institute Development Institute

  20. Production Infrastructure Oil and Gas Production for Technicians Production Platform Types The infrastructure required for drilling in onshore and offshore operations are similar to those used for exploration. Management Development and Petroleum Skills Productivity Institute Development Institute

  21. Production Infrastructure Oil and Gas Production for Technicians Onshore ‘Platform’ The picture shows a well equipped with a sucker rod pump (donkey pump) often associated with onshore oil production. Management Development and Petroleum Skills Productivity Institute Development Institute

  22. Production Infrastructure Oil and Gas Production for Technicians Offshore Platforms • In offshore production, normally, a permanent steel platform is installed to serve as the gathering and processing centre for the wells from the platform. If the field is large enough, additional ‘satellite’ platforms may be needed, linked by subsea flow lines to the central facility. Management Development and Petroleum Skills Productivity Institute Development Institute

  23. A Shallow Water Complex Oil and Gas Production for Technicians Production Infrastructure In shallow water areas, typically a central processing facility is supported by a number of smaller wellhead platforms that include Wellhead Platform, Riser Platform, Processing Platform, Accommodation Platform and Power Generation Platform. BGas Morecambe Field Management Development and Petroleum Skills Productivity Institute Development Institute

  24. Oil and Gas Production for Technicians Production Infrastructure Deeper Water Steel Platform Management Development and Petroleum Skills Productivity Institute Development Institute

  25. Oil and Gas Production for Technicians Production Infrastructure Concrete Platform Management Development and Petroleum Skills Productivity Institute Development Institute

  26. Floating, Production, Storage and Offloading (FPSO) Oil and Gas Production for Technicians FPSOs are standalone structures that do not need external infrastructure such as pipelines or storage facilities. An FPSO is typically a tanker type hull or barge, often converted from an existing crude oil tanker, with capacity for processing and storing oil. Crude oil is offloaded to a shuttle tanker at regular intervals, from days to weeks, depending on production and storage capacity. Due to the increasing sea depth for new fields, FPSOs dominate new offshore field development at more than 1000 meters water depth. Management Development and Petroleum Skills Productivity Institute Development Institute

  27. Floating, Production, Storage and Offloading (FPSO) Oil and Gas Production for Technicians Management Development and Petroleum Skills Productivity Institute Development Institute

  28. Oil and Gas Production for Technicians Management Development and Petroleum Skills Productivity Institute Development Institute JUBILEE FIELD DEVELOPMENT • Significant oil/gas find off Cape Three Points by Consortium of Kosmos, Tullow, Anadarko, Sabre and GNPC announced in June/September 2007. • Two blocks in pressure communication and hence being treated as same reservoir. Unitized as the Jubilee Field. • Water Depth of 1000m-1700m, 65km offshore. • Development based on about 600- 1800mbo of light crude oil with associated gas.

  29. Oil and Gas Production for Technicians JUBILEE FIELD PRODUCTION (Artist Impresion) Source: GNPC Management Development and Petroleum Skills Productivity Institute Development Institute

  30. Oil and Gas Production for Technicians FPSO KWAME NKRUMAH Management Development and Petroleum Skills Productivity Institute Development Institute The FPSO receives oil/gas from sub sea wells, processes it on board and then exports it to a refinery by shuttle tankers. The FPSO is about 60 meters wide and 330 meters in length – approximately the length of three football fields with storage capacity of 1.6 million barrels.

  31. Oil and Gas Production for Technicians FPSO Kwame Nkrumah MV21 Management Development and Petroleum Skills Productivity Institute Development Institute

  32. Oil and Gas Production for Technicians Oil and Gas Production - Process The simplified schematic diagram shows a typical production process using one stage separation. Most installations however have several separation stages to achieve the standards required for export oil and gas. Management Development and Petroleum Skills Productivity Institute Development Institute

  33. Oil and Gas Production for Technicians Typical Oil/Gas Production Flow Diagram Management Development and Petroleum Skills Productivity Institute Development Institute

  34. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Production and Test Manifold • Individual well streams are brought together in gathering pipelines for onshore installations, or via multiphase pipeline risers to production manifolds on offshore facilities. Management Development and Petroleum Skills Productivity Institute Development Institute

  35. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) • In most cases well fluids are a combination of gas, oil and water and various contaminants that have to be separated, cleaned and processed. The production process includes the following: Separation, Gas Compression, Metering, Storage and Export, and Utility Systems. Management Development and Petroleum Skills Productivity Institute Development Institute

  36. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Separation may consist of the following types of separators: Test separators Production separators Second stage separator Third stage separator Coalescer Management Development and Petroleum Skills Productivity Institute Development Institute

  37. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Test Separator • They are used to separate well flow from one another to enable analysis and detailed measurements of each well to be made. • Test separators can also be used to produce fuel gas for power generation when the main process is shut down. Management Development and Petroleum Skills Productivity Institute Development Institute

  38. Separator Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Management Development and Petroleum Skills Productivity Institute Development Institute

  39. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Production Separator • Generally of the gravity type as shown. With this horizontal type separator, the well fluids are fed and retained for a while, about 5 minutes, to allow the gas to bubble out at the top, oil to be taken out in the middle and for the water to sink to the bottom. Management Development and Petroleum Skills Productivity Institute Development Institute

  40. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Example of Production Separator The separator shown here is the gravity types. (See how gas, oil and water are separated by their “weight”). Management Development and Petroleum Skills Productivity Institute Development Institute

  41. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Production Separator (Cont’d) Fluid pressure is normally reduced in several stages to allow controlled separation of volatile components, eg. In high and low pressure separators, etc. Management Development and Petroleum Skills Productivity Institute Development Institute

  42. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Second Stage Separator The second stage separator is similar to the first stage high pressure separator. It receives the output from the first separator and also production from wells that are connected to the low pressure manifold. A heater may be used to raise the temperature, thereby making it easier to remove more of the water from the hydrocarbon. Management Development and Petroleum Skills Productivity Institute Development Institute

  43. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Third Stage Separator Affords additional opportunity to reduce pressure to enable more heavy gas components to boil out, and also heat the liquid to obtain improved separation of heavy components. Management Development and Petroleum Skills Productivity Institute Development Institute

  44. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Coalescers Coalescers use high electric field strength to further remove water from the oil. Electrostatic Desalters When the separated oil still contains unacceptably high amounts of salts, eg. sodium, calcium, magnesium chlorides, they are removed using electrostatic desalters. Management Development and Petroleum Skills Productivity Institute Development Institute

  45. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Gas Treatment and Compression Raw natural gas normally contains other hydrocarbons, eg. ethane, propane, butane, pentanes, etc. Raw natural gas also contains water, hydrogen sulphide, carbon dioxide, helium, nitrogen, etc. During natural gas processing, all the fluids and various hydrocarbons are separated to leave pure natural gas, normally called ‘pipeline quality’ dry natural gas before transmission. Management Development and Petroleum Skills Productivity Institute Development Institute

  46. Oil and Gas Production for Technicians Oil and Gas Production – Process (Cont’d) Gas Treatment and Compression (Cont’d) Scrubber: After the gas has been cooled in Heat Exchangers, it is passed through Scrubbers to remove droplets of liquids. The most commonly used scrubber is based on dehydration by absorption in Triethylene Glycol (TEG). The associated hydrocarbons, normally called natural gas liquids (NLGs) are used as raw materials for oil refineries, petrochemical plants or as sources of energy. Management Development and Petroleum Skills Productivity Institute Development Institute

  47. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Gas Treatment and Compression (Cont’d) • Gas from separators would have lost so much of its initial pressure that it must be compressed, using turbine or electric driven compressor, before the gas can be exported. Management Development and Petroleum Skills Productivity Institute Development Institute

  48. Oil and Gas Production – Process (Cont’d) Oil and Gas Production for Technicians Water Treatment The water from the separators and coalescers are further cleaned to remove sand and oil droplets before use or discharge into the sea. Management Development and Petroleum Skills Productivity Institute Development Institute

  49. Oil and Gas Production for Technicians Measuring Meters Storage, Metering and Export Most production facilities do not store gas but have provision for storage of oil before its export. Storage facilities depend on the type of installation. Some use the base of platforms, hull of FPSOs or the oil is piped to onshore tank farms where it’s metered to determine volume as part of the custody transfer process. Management Development and Petroleum Skills Productivity Institute Development Institute

  50. Oil and Gas Production for Technicians Utility Systems They are systems that do not handle hydrocarbon process flow, but provide facilities for process safety or for residents of the installation. Depending on the location of the plant, the utility system may come from nearby facility or be generated onsite for remote installations. Management Development and Petroleum Skills Productivity Institute Development Institute

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