Introduction to Oilfield Facilities and Processes

1. Sokono Engineering Services Introduction to Oilfield Facilities and Processes by Engr. Ogbarode N. Ogbon

2. Surface Facilities Processes • Reservoir Fluid Processing • Separation of reservoir fluid into its component phases and processing of separated phases/products to sellable, reusable or disposable quality

3. Typical Surface Facilities and Processes

4. Surface Facilities Processes • Gas Processing • Removal of Contaminants • Removal of Water Vapour • Removal of Condensate and Hydrocarbon Vapour • Crude Oil Processing • Removal of Water/Salt • Removal of Contaminants • Emulsion Treatment • Water Treatment • Removal of Hydrocarbons • Removal of Contaminants • Sediments (Solids) Treatment • Removal of Hydrocarbons

5. Surface Facilities • Typical Nigerian Oil and Gas Field Facilities Operations • Gathering System • Transport (gather) reservoir Fluid from individual wells to Production Inlet Manifold • Flowstation or Gathering Station • Separates Oil, Gas & Water phases from reservoir fluid • Treats Emulsion • Treats (when necessary) crude oil to sale quality and store • Treats (when necessary) Produced water to disposal quality • Meters and Pumps out treated phases • Compresses (when necessary) Natural Gas for Injection • Flares Natural Gas • Oil Terminal • Treats Crude oil to Sales Quality, Stores and Pumps out to Customers • Treats Produced water to disposal Quality and Disposes • Treats Solids to disposal quality and disposes

6. Surface Facilities • Typical Nigerian Oil and Gas Field Facilities Operations • Pumping Station • Increases Liquid(oil & water) Pressure for mobility • Natural Gas Processing Facilities • Hydrocarbon Liquid Dewpointing Facility • Refrigeration Facilities • Compression refrigeration Plant • Pressure Reduction(Expansion) Refrigeration • – Joule-Thompson and Turbo Expanders. • Sweetening (Contaminants Removal) Facility • Dehydration (Water Removal) Facility • Compression Facilities • Compression Station • Compressed Natural Gas (CNG) Facility

7. Surface Facilities • Typical Nigerian Oil and Gas Field Facilities Operations • Liquefied Natural Gas Facility • Turns natural gas to liquid state for the purpose of transportation • Gas to Liquid (GTL) Facility • Chemical production of petroleum products from natural gas • Nitrogen Rejection Facility • Solvent absorption of hydrocarbon fro natural gas to produce nitrogen

8. Flowstation or Gathering Station • Definition • Oil and Gas Production Facility that receives Reservoir Fluid from Gathering lines from oil field Wells, Processes it and Pumps it to final processing centers or Storage tanks for sale • Level of Oil and Gas Processing is determined by Operators’ Overall Operations Strategy/Philosophy • It also consists of equipment for process control, power generation, lighting, etc. • They are sometimes referred to as Early Production Facilities or Primary Production Facilities

9. Flowstation or Gathering Station • Basic Operating Components

10. Typical Flow Station Facilities and Processes

11. Flowstation Operations Production & Well Test Manifold Operations • What is Manifold ? • A construction of pipes and valves to receive reservoir fluid from different wells, co-mingling and directing same to production vessel • Manifold Components • Gathering Lines • Well Ligament • Flow Control Valves • Production Heads Well Flowlines Entering Manifold Gathering Lines Well Ligament Production Headers

12. Flowstation Operations Surge Vessel Test Separator HP Separator LP Separator Stage Separation • Separators arrangement in two-stage separation process

13. Flowstation Operations • Production of oil and gas wells • To check, record and monitor flowline pressure and temperatures of each producing well connected to the manifold header. • To take corrective actions instantly if there is any abnormal increase or decrease . • To take corrective actions incase of minor or major operational disorder, to ensure smooth running of the plants at the shortest possible time. • All critical situations should be mutually discussed with company's Manager. • To maintain all the manifold header valves in perfect operative condition.

14. Flowstation Operations • To execute all preventive maintenance schedules provided by the company. • To execute all repairing jobs including general maintenance of the valves, leakage in the manifold, gas/oil separators, etc. • To monitor pilot fire at the flare stack and carry out flaring when necessary. • To monitor closely, record in log book and maintain desired Separator operating back pressure at all time during plant operation. • To closely monitor the proper functioning of all pressure vessels to ensure that no carry over of water or condensate or blow by of gas shall take place. • To closely monitor the proper functioning of auto/manual drain valves installed in the various pressure vessels.

15. Flowstation Operations • To monitor and maintain record of Oil, Condensate, Gas and water production and Dispatch the same through approved channel. • To ensure stock of Fire fighting water when required and ALL fire fighting equipment/vehicles are in working condition. • To ensure availability of instrument air/gas and that the SCADA system and all Process Control Systems are in good working condition. • House keeping and up-keepment of the stations. • To carryout periodical internal safety audit for the stations as per safety check list. • Preparation & maintaining of records on various safety parameters and statutory records pertaining to HS & E. • Preparation of well performance report on daily basis and conciliation of production statement.

16. Flowstation Operations • Basic Operating Components • Gathering Lines from Field Wells • Manifold • Stage Separators • Test Separator • Surge Tank • Chemical Injection Unit(e.g. Hydrate Inhibitor) • Emulsion Treating Vessel • Metering Skid • Process Control Devices

17. Flowstation Operations • Basic Processes and Operations at Typical Flowstation • Day to day monitoring of the producing wells • Gathering of well production parameters • Servicing of wellhead equipment, manifold and fittings • Managing well production as per operations and market demand • Carrying out well oil flow, pressure, temperature and other tests • Associating with well commissioning and workover operations of the wells as and when required • Carrying out any job pertaining to the operation and management of the wells

18. Flowstation Operations • Basic Processes and Operations at Typical Flowstation • Manifold Operations • Separation Process  Degassing or Dry Crude Production • Emulsion Treatment • Produced Water Treatment • Chemical Injection • Pumping • Metering • Gas Flaring • Process Control

19. Production, Well Test & Manifold Operations • Manifold Components

20. Production, Well Test & Manifold Operations • Manifold Operations • Receives Reservoir Fluid from individual well • Wells may individually be placed on test and/or production. • Fluid Valve Control or Direction to respective pressure range header • Co-mingling of ALL Fluids from Wells of Same Pressure Range • Header Fluid flows to respective Production Vessel(Separator) • Individual Well Fluid Flow Parameter Measurement & Monitoring • They may be manually operated or automatically operated with valves with automatic timers.

21. Production, Well Test & Manifold Operations • Manifold Operations • They are designed for various ANSI and API design pressures and various pipe sizes ratings • Fixed or adjustable and manual or automated Chokes can be included for pressure reduction. • Other instrumentation and controls can be provided per customer specifications