1. OVERVIEW: OIL & GAS INDUSTRIES, UPSTREAM PRODUCTION FACILITIES (FSF/FPF/CPF)

2. OUTLINE  Introduction  Field Surface Facilities (FSF)  Field Production Facilities (FPF)  Central Processing Facilities (CPF)  Control System  Power Generation and Distribution

3. Crude Oil Characteristics What is Oil? Crude oil is a mixture of carbon (84%), hydrogen (14%), sulfur (1-3%), and nitrogen, oxygen, metals, and salts (less than 1%). Crude oil is processed to remove unwanted materials and produce products such as motor gasoline, diesel, jet and home heating fuels, waxes, asphalt, feedstock and other components. Ust. Satmon J. Timayo3

4. Some of the non hydrocarbon compounds present in crude oils can pose major problems in the processing and handling of crude oils. These includes but is not limited to: 1. Sulfur compounds 2.Nitrogen compounds 3.Oxygen compounds and 4.Metallic compounds Ust. Satmon J. Timayo4

5. Some hydrocarbon compounds found in crude oils can also pose major processing and handling problems such as. 1.Aromatics 2.Asphaltenes 3.Naphthenes 4.Wax 5.Petroleum acids and 6.Porphyrins containing Vanadium, nickel etc. Ust. Satmon J. Timayo5

6. Crude Oil Production: Sources of water in Crude Oil Geology tells us that crude oil is formed over millions of years within what is known as “source rocks”. It is generally theorized that gas, oil and salt water occupy pore spaces between the grains of sandstones or pore spaces between grains of limestone's and dolomites which form the source rock. Ust. Satmon J. Timayo6

7. The rocks containing the gas, oil and salt water are sealed by a layer of impermeable rock, trapping the petroleum accumulating within the confines of the source rock and forming the reservoir. Under the effects of pressure and gravity from the source rock the gas and oil migrate until they are trapped in another capped seal rock. Because of the differences in densities, gas, oil and water segregate within the trap rock. Gas if present will occupy the upper part of the trap and water occupies the bottom part of the trap while the oil is trapped in between the gas and water. Ust. Satmon J. Timayo7

8. Some salt water stays with the gas and or oil within the pore spaces and as a film covering the surfaces of the rock grains and this water is known as connate water, and it may occupy from 10% up to 50% of the pore volume. Much of the crude oil is derived from sandstone formations. Ust. Satmon J. Timayo8

9. These formations consist of combinations of silicon and oxygen that tend to form as partially charged, anionic (negatively charged) crystallites. These crystallites have a high affinity for water and are often found in close association with water. This close association is due to the phenomenon of hydrogen bonding, where the partially positive hydrogen of the water interacts with the partially negative oxygen of the silicate (Si n O 2n ). Ust. Satmon J. Timayo9

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11. What is Natural Gas? Natural gas occurring underground is composed largely of methane (70-90%) and other hydrocarbons such as ethane, propane and butane. However, at natural gas processing facilities, most of these other substances are separated out so that the natural gas that we use is composed almost entirely of methane. Natural gas can be produced from either natural gas wells, which primarily produce raw natural gas, or from oil wells where natural gas is recovered along with oil. Natural gas can also be produced from coal-bed methane (CBM) wells. Coal-bed methane, a type of natural gas, is located within coal seams. To be extracted, the seam has to be depressurized by pumping huge volumes of groundwater to the surface. According to one Montana Department of Environmental Quality study, a single well can produce more than 23,000 gallons of water a day. The water has been difficult to manage because of the large quantity and the potential for poor quality - it contains sodium and other salts that can kill plants and damage soil. Ust. Satmon J. Timayo11

12. Ust. Satmon J. Timayo12

13. PETROLEUM PRODUCTION PROCESS

14. PRODUCTION AND PROCESS FACILITIES CPF FPF Field 2 FPF Field 1 FPF Field 3 FPF FSF Marine Terminal = OGM Wellhead

15. WELLHEAD  Maintains surface control using choke  Prevent well fluids from leaking or blowing at the surface  Design to withstand pressures of up to 140 MPa(1400  Consist of three components, I.Casing head II.Tubing head III.Christmas Tree

16. WELLHEAD

17. OIL GATHERING MANIFOLD (OGM)  It serves two purposes: I.To collect production from several individual wells and direct it via a production manifold to a gathering line, a gathering station, or a field pump station II.To direct production via a test header from a selected well to a well test skid located at each manifold  Located adjacent to a producing well

18. ELECTRIC SUBMERSIBLE PUMPS  Electrically driven and submersible  Consist of three units I. Electric Motor II. Protector III. Multistage Centrifugal Pump  Operation is controlled by a control box

19. ELECTRIC SUBMERSIBLE PUMPS  Designed to pump at very high flow rates (100 to 10,000 BPD)  Less efficient than other types  Expensive  Sensitive to solids and free gas  If conditions are favorable, ESPs can run several years

20. PROGRESSIVE CAVITY PUMPS  PCP Pumps

21. SEPARATORS  Mechanical devices where gas is flashed from the liquids and “free water” is separated from the oil  Can be either horizontal, vertical and spherical in configuration  Two types, Production separator and Test separator  Can be either two phase and three phase separator  Most oil contracts specify a maximum percent of basic sediment and water (BS&W) that can be in the crude  Typically vary from 0.5% to 3% depending on location  Water from the separators must be treated to remove small quantities of produced oil

22. SEPARATORS

23. STAGING OF SEPARATORS

24. TWO PHASE SEPERATORS

25. THREE PHASE SEPERATORS Gas Oil Gas Water Oil Feed Water Demister Weir

26. COMPRESSOR  Consist of I. Scrubbers- remove liquid droplets II. Heat Exchangers

27. HEAT EXCHANGERS

28. DEHYDRATOR/DESALTER  Dehydration  Desalting  Consists of three primary steps I. Injection of wash water II. Contact between the wash water and the soluble salts, and III. Separation of the aqueous phase – most of the installed hardware is involved in the phase separation step

29. DEHYDRATOR

31. DESALITNG

32. FLARE SUBSYSTEM  Include Flare, atmospheric ventilation and blow down  Provide safe discharge and disposal of gases and liquids resulting from: I. Spill-off flaring from the product stabilization system (Oil, Condensate etc.) I. Production testing II. Relief of excess pressure caused by process upset conditions and thermal expansion I. Depressurization either in response to an emergency situation or as part of a normal procedure I. Planned depressurization of subsea production flowlines and export pipelines

33. FLARE SUBSYSTEM

34. METERING SKID

35. BOOSTER PUMPS

36. DESANDERS

37. SKIM TANKS

38. WATER INJECTION UNITS

39. GAS KNOCKOUT DRUM

40. INDUCED GAS FLOTATION UNITS

41. CONTROL SYSTEM  Provide automatic day-to –day control of oil field production system  Supervisory Control and Data Acquisition (SCADA)- which monitors and controls and DCS  Consists of the following subsystems; I. A human–machine interface (HMI) II. A computer system III. Remote terminal units (RTUs) IV. Programmable logic control (PLCs) V. Communication infrastructure VI. Various process and analytical instrumentation

42. CONTROL SYSTEM (PLCs)

43. CONTROL SYSTEM

44. TYPICAL BASIC SCADA

46. POWER GENERATION AND DISTRIBUTION  Provided from main power or from local diesel generator sets  Large facilities have great power demands, from 30 MW and upwards to several hundred MW  Voltage levels for High, Medium and Low voltage distribution boards are 13- 130kV, 2-8 kV and 300- 600 V respectively  Power is generated and exchanged with mains or other facilities on the HV distribution board  Relays for protection functions

47. POWER GENERATION AND DISTRIBUTION

48.  Power management system is used for control of electrical switchgear and equipment  Includes HV, MV and LV low voltage switchgear  Motor Control Centers (MCC) and emergency generator sets

49. THANK YOU