Offshore Oil and Gas

Production Systems
 OFFSHORE PRODUCTION SYSTEM‐ A SCHEMATIC

DATA/SCADA
SBM TANKER
POWER
UMBILICAL(DATA/WELL CONTROL) LIFT GAS OIL TO REFINERY
WELL P/F'S
PROCESS OIL ONSHORE
WELL FLUID INJETCTION WATER
PLATFORMS TERMINALS
INJ. WATER GAS GAS TO CONSUMERS
WELL FLUID
W
LIFT GAS (OIL/GAS/WATER)
WELLS WELLS WELLS/CONNECTED WELL P/F
OIL PRODUCERS WELL TESTING SEPARATION MODULE‐ OIL/GAS/WATER
GAS PRODUCERS PRODN OPTIMIZATION GAS COMPRESSION AND DEHYDRATION MODULE
INJECTION WELLS WELL CONTROL SEA WATER TREATMENT FOR WATER INJECTION
WELL SERVICING PRODUCED WATER TREATEMENT MODULE
TELEMETRY / SCADA POWER GENERATION
UTILITIES ‐ WATER/SUPPLIES
LIVING QUARTERS
DRILLING/WELL SERVICING RIG MODULE
 THE MAJOR ELEMENTS OF OFFSHORE
PRODUCTION SYSTEM

• WELLS (SUBSEA/PLATFORM WELLS)

• WELL PLATFORMS/WELL SERVICING RIGS

• FEEDER SUBSEA PIPELINES

• PROCESSING PLATFORMS

• EXPORT PIPELINES FOR OIL/GAS

• TANKERS FOR EVACUATION OF OIL.

We shall discuss about…

• PLATFORMS
• WELLHEAD PLATFORMS
• WELLS
• PROCESSING SYSTEM
• NEW TECHNOLOGIES
TYPES OF OFFSHORE PLATFORMS
WATER DEPTH AND TYPE OF PLATFORM
 Oil platforms
• An oil platform or oil rig is a large structure used to house
workers and machinery needed to drill and/or extract oil and
natural gas through wells in the ocean bed.
• Depending on the circumstances, the platform may be attached
to the ocean floor, consist of an artificial island, or be floating.
• Generally, oil platforms are located on the continental shelf,
though as technology improves, drilling and production in
deeper waters becomes both feasible and profitable.
• A typical platform may have around thirty wellheads located on
the platform and directional drilling allows reservoirs to be
accessed at both different depths and at remote positions up to
5 miles (8 kilometres) from the platform.
• Many platforms also have remote wellheads attached by
umbilical connections, these may be single wells or a manifold
centre for multiple wells.
FIXED PLATFORMS
These platforms are built on concrete and/or steel legs
anchored directly onto the seabed, supporting a deck
with space for drilling rigs, production facilities and
crew quarters.

Such platforms are, by virtue of their immobility,

designed for very long term use.

Various types of structure are used, steel jacket,

concrete caisson, floating steel and even floating
concrete.

Steel jackets are vertical sections made of tubular steel

members, and are usually piled into the seabed.
Concrete caisson structures, often have in‐built oil
storage in tanks below the sea surface and these tanks
were often used as a flotation capability, allowing them
to be built close to shore and then floated to their final
position where they are sunk to the seabed.

Fixed platforms are economically feasible for

installation in water depths up to about 1,700 feet (520
m).
Fixed Platform
Semi‐submersible Platform
These platforms have legs of sufficient
buoyancy to cause the structure to float,
but of weight sufficient to keep the
structure upright.

Semi‐submersible rigs can be moved from

place to place; can be ballasted up or down
by altering the amount of flooding in
buoyancy tanks;

They are generally anchored by with chain,

wire rope and/or polyester rope during
drilling operations, though they can also be
kept in place by the use of dynamic
positioning.

Semi‐submersibles can be used in water

depths from 200 to 10,000 feet (60 to
3,050 m).
Jack‐up Platforms
Jackups, as the name suggests, are platforms
that can be jacked up above the sea using legs
which can be lowered like jacks.

These platforms are typically used in water

depths up to 400 feet, although some designs
can go to 550 feet depth.

They are designed to move from place to

place, and then anchor themselves by
deploying the legs to the ocean bottom using a
rack and pinion gear system on each leg.
Compliant Towers
• These platforms consist of narrow,
flexible towers and a piled foundation
supporting a conventional deck for
drilling and production operations.
Compliant towers are designed to
sustain significant lateral deflections
and forces, and are typically used in
water depths ranging from 1,500 and
3,000 feet (450 and 900 m).
Drillships
A drillship is a maritime vessel that has
been fitted with drilling apparatus. It is
most often used for exploratory drilling of
new oil or gas wells in deep water but can
also be used for scientific drilling. Early
versions were built on a modified tanker
hull, but purpose‐built designs are used
today. Most drillships are outfitted with a
dynamic positioning system to maintain
position over the well. They can drill in
water depths up to 12,000 feet (3,660 m).
Floating production systems
FPSOs are large ships equipped with
processing facilities and moored to a location
for a long period.

The main types of floating production systems

are:

FPSO (floating production, storage, and

offloading system),

FSO (floating storage and offloading

system), and

FSU (floating storage unit).

These ships do not actually drill for oil or gas.

FPSO AND SUBSEA WELLS
Tension‐leg platform
TLPs consist of floating rigs tethered to the
seabed in a manner that eliminates most of the
vertical movement of the structure.

TLPS are used in water depths up to about 6,000

feet (2,000 m). The "conventional" TLP is a 4‐
column design which looks similar to a
semisubmersible.

Proprietary versions include the Seastar and

MOSES mini TLPs; they are relatively low cost,
used in water depths between 600 and 4,300
feet (200 and 1,300 m).

Mini TLPs can also be used as utility, satellite or

early production platforms for larger deepwater
discoveries.
SPAR Platforms
Spars are moored to the seabed like the TLP, but
whereas the TLP has vertical tension tethers the Spar
has more conventional mooring lines.
Spars have been designed in three configurations:
the "conventional" one‐piece cylindrical hull, the
"truss spar" where the midsection is composed of
truss elements connecting the upper buoyant hull
(called a hard tank) with the bottom soft tank
containing permanent ballast, and the "cell spar"
which is built from multiple vertical cylinders.
The Spar may be more economical to build for small
and medium sized rigs than the TLP, and has more
inherent stability than a TLP since it has a large
counterweight at the bottom and does not depend
on the mooring to hold it upright.
It also has the ability, by use of chain‐jacks attached
to the mooring lines, to move horizontally over the
oil field.
World’s deepest spar: Eni's Devil's Tower is located
in 5,610 feet (1,710 m) of water, in the Gulf of
Mexico; however, when Shell's Perdido Spar is
installed, it will be the deepest at 8,000 feet (2,438
m
 Maintenance and supply
• A typical oil production platform is self‐sufficient in energy and water needs,
housing electrical generation, water desalinators and all of the equipment
necessary to process oil and gas such that it can be either delivered directly
onshore by pipeline or to a Floating Storage Unit and/or tanker loading facility.
• Elements in the oil/gas production process include wellhead, production
manifold, Production separator, glycol process to dry gas, gas compressors,
water injection pumps, oil/gas export metering and main oil line pumps.

• All production facilities are designed to have minimal environmental impact.

• Larger platforms are assisted by smaller ESVs (emergency support vessels) that
are summoned when something has gone wrong, e.g. when a search and
rescue operation is required.

• During normal operations, PSVs (platform supply vessels) keep the platforms
provisioned and supplied, and AHTS vessels can also supply them, as well as
tow them to location and serve as standby rescue and fire fighting vessels.
 Crew
• The size and composition of the crew of an offshore
installation will vary greatly from platform to platform.

• Because of the cost intensive nature of operating an offshore

platform, it is important to maximise productivity by ensuring
work continues 24 hours a day.

• This means that there are essentially two complete crews on

board at a time, one for day shift and the other for night shift.
Crews will also change out at regular intervals, nominally two
weeks.
 Essential personnel
• Not all of these personnel are present on every platform, on smaller platforms workers will be responsible
for several areas. The names shown are not industry‐wide.

* OIM (offshore installation manager) is the ultimate authority during his/her shift and makes the
essential decisions regarding the operation of the platform.
* Operations Team Leader (OTL)
* Offshore Operations Engineer (OOE) is the senior technical authority on the platform
* PSTL or Operations coordinator for managing crew changes
* Dynamic Positioning Operator, navigation, ship or vessel maneuvering (MODU), station keeping,
fire and gas systems operations in the event of incident
* 2nd Mate ‐ Meets manning requirements of flag state, operates Fast Rescue craft, cargo ops, fire
team leader.
* 3rd Mate ‐ Meets manning requirements of flag state, operates Fast Rescue craft, cargo ops, fire
team leader
* Ballast Control Operator _ also fire and gas systems operator
* Crane operators to operate the cranes for lifting cargo around the platform and between boats.
* Scaffolders to rig up scaffolding for when it is required for workers to work at height.
* Coxwains for maintaining the lifeboats and manning them if necessary.
* Control room operators ‐ Especially FPSO or Production platforms.
* Catering crew will include people tasked with performing essential functions such as cooking,
laundry and cleaning the accommodation.
* Production techs for running the production plant
* Helicopter Pilot(s) live on some platforms that have a helicopter based offshore. The helicopter
flight crew transports workers to other platforms or to shore on crew changes.
* maintenance technicians (instrument ,electrical ,mechanical )
 Essential personnel – ONGC System
MANAGERS:
• OFFSHORE INATALLATION MANAGER
• PROCESS MANAGER
• MAINTENANCE MANAGER
• WELL PLATFORM MANAGER
• HSE MANAGER

TEAMS
• Process control room operators
• Mechanical/Electrical/Instrumentation team
• Static Equipment maintenance team
• Wellhead teams
• Pipeline maintenance team
• Skilled and Unskilled technicians
 Incidental personnel
* Drill crew will be on board if the installation is performing drilling
operations. A drill crew will normally comprise:

o Toolpusher
o Roughnecks
o Roustabouts
o Company man
o Mud engineer
o Derrickhand
o Geologist

* Well services crew will be on board for well work. The crew will
normally comprise:

o Well services supervisor

o Wireline or coiled tubing operators
o Pump operator
 Risks
• The nature of their operation — extraction of volatile substances
sometimes under extreme pressure in a hostile environment — has
risk and accidents and tragedies occasionally occur. In July 1988,
167 people died when Occidental Petroleum's Piper Alpha offshore
production platform, on the Piper field in the North Sea, exploded
after a gas leak. The accident greatly accelerated the practice of
providing living accommodations on separate rigs, away from those
used for extraction.
However, this was, in itself, a hazardous environment. In March
1980, the 'flotel' (floating hotel) platform Alexander Kielland
capsized in a storm in the North Sea with the loss of 123 lives.
Given the number of grievances and conspiracy theories that
involve the oil business, and the importance of gas/oil platforms to
the economy, platforms are believed to be potential terrorist
targets. Agencies and military units responsible for maritime
Security often train for platform raids.
 Ecological effects
• In British waters, the cost of removing all platform rig structures entirely was estimated in
1995 at $345 billion, and the cost of removing all structures including pipelines — a so‐called
"clean sea" approach — at $621 billion.

• Further effects are the leaching of heavy metals that accumulate in buoyancy tanks into
water; and risks associated with their disposal.

• There has been concern expressed at the practice of partially demolishing offshore rigs to
the point that ships can traverse across their site; there have been instances of fishery
vessels snagging nets on the remaining structures.

• Proposals for the disposal at sea of the Brent Spar, a 449 ft tall storage buoy , was for a time
in 1996 an environmental cause célèbre in the UK after Greenpeace occupied the floating
structure. The event led to a reconsideration of disposal policy in the UK and Europe.

• In the United States, Marine Biologist Milton Love has proposed that oil platforms off the
California coast be retained as artificial reefs, instead of being dismantled (at great cost),
because he has found them to be havens for many of the species of fish which are otherwise
declining in the region, in the course of 11 years of research. Love is funded mainly by
government agencies, but also in small part by the California Artificial Reef Enhancement
Program.
• In the Gulf of Mexico, more than 200 platforms have been similarly converted.
Un-manned Platforms
Normally unmanned installations….
• These installations (called
Wellhead Platforms), are
small platforms, consisting of
little more than a well bay,
helipad and emergency
shelter.
• They are designed to operate
remotely under normal
operations, only to be visited
occasionally for routine
maintenance or well work.
 WELLHEAD PLATFORMS
• Generally 4 legged unmanned platforms
• Consists of 4 decks, spider deck, cellar deck, main deck and helideck
• Personnel visit the platform for Well testing and other maintenance
activities.
• May have 3 to 32 wells (Producers and Injectors), one vertical well and
others directional and reaching out in different direction up to 6 km
from the platform.
• Wells are drilled normally by Jack up Rigs that dock with the platform.
• Well servicing (workover) is done either by Jack up rigs or by Modular
Rigs that are assembled over the platform.

JACK‐UP RIG DOCKED ON WELL PLATFORM FOR SOLAR PANELS POWER THE WELL PLATFORMS
DRILLING/WELL SERVICING
 Facilities in Well Platforms
• Wells
• Production Manifold to receive well fluid from all the wells
• Lift gas Manifold for feeding lift gas to well along with Injection gas
regulation/Control and measurement system.
• WI manifold for feeding injection water to WI wells along with metering system.
• Test manifold and Test separator and associated measurement system for Oil, Gas
and Water.
• Well control Panel (SDP)
• Instrument gas system
• RTU and SCADA
• Battery pack, Solar power panel.
• Subsea lines carry well fluid from the platform to the Process platform
• Also, Lift gas and Injection water is brought in by subsea lines from Process
Platform.
• Emergency Gen‐set.
• Fire water pumps and Fire fighting system.
• HC Gas detectors
• ESD/FSD system
• Crane.
 SDP
• Pneumatic control panels are designed to monitor crucial wellhead safety parameters.
They provide sequential start up and safe shutdown of production wells.
• In remote unmanned well‐head platforms produced gas is used as the medium inside the
control panel. Easy availability of pneumatic power source makes pneumatic controls a
desirable choice.
The pneumatic shutdown panel is designed as a central protection unit for overall protection
of the installation. Three levels of protection for personnel, production wells and surface
facilities are envisaged. Thus a panel consists of;

a) Fire and gas leakage protection system: Any gas leakage is automatically detected and
appropriate shutdown action initiated to prevent formation of combustible mixture. All
sources of ignition are also shutdown. Any eruption of fire is detected and appropriate
shutdown and suppression action initiated.

b) Surface Facility Protection: A safety analysis or hazardous operability (HAZOP) analysis of

surface facilities including rotary and process equipments is carried out. All possible hazards,
interrelation between various parameters are identified and listed. The functional chart thus
evolved is the SAFE (Safety Analysis and Function Evaluation) chart. The SAFE chart forms the
basis for design of panel in surface safety protection.

c) Well control & Protection: A major function of the wellhead shutdown panel is to control
the well through the surface and sub surface safety valves. The interrelations between various
valves are well defined and their sequential operation established.
 WELL CONTROL‐SCHEMATIC
FSD‐ FIRE SHUTDOWN‐ FUSIBLE
PLUG LOOP

WELL ‐ XMAS SSV‐ SUFRACE

TREE SAFETY VALVE

PNEUMATIC PRESSURE TO SSV

HC
DETECTORS

PNEUMATIC SUPPLY

GI SHUTDOWN PRESSURE SWITCH

VALVE HIGH LOW
RADIO
ESD SIGNAL
HYDRAULIC PRESSURE TO SSSV
WELL CONTROL RTU (REMOTE TELEMETRY
SDP REMOTE UNIT)
WELL FLOW CONTROL

PNEUMATIC SUPPLY

SURFACE CONTROLLED SUB‐SURFACE

LIFT GAS SAFETY VALVE ‐ 150 M FROM P/F DECK
 WELL CONTROL
• Wells close by SSV (Surface Safety Valve) and SSSV
(Sub‐surface Safety Valve) when abnormal
conditions exists.

• Abnormal conditions may be Higher Pressures in the

flow lines, Fire.

• Wells can also be closed remotely from Process

platforms/Shore through SCADA with the help of
RTU.
 SMART WELLHEAD PLATFORMS
• Provides Well head real time data.

• Provide Real time Monitoring and Control of Unmanned

Platforms and wells.

• Provides minimum Human Intervention in day to day operations

• Provide Stabilised production and Transportations process along
with Optimisations

• Provide real time data Consolidation, Recording and storage for

the analysis for future evaluations.

• Reduce the delay in decision making via online measurements of

critical parameters such as Water cut, Gas Rates etc.
 Major Elements of SMART platform
• Instrumentation on well head.

• Automated Well testing using Remotely Operated Multi Selector

Valve in well platform.

• Automation system to Monitor and Optimise Production.

• Remote Lift Gas optimization.

• Integration of different automation system to ensure data

consolidation at central facilities.

• WAN Communication: Radio, V‐ sat at offshore wellhead platform.

 WELLS
• Producers
Self flow, Gas lifted and ESP.
• Injectors
• Subsea wells :
Dry Tree, Wet Tree wells.
• Directional wells
• Horizontal wells
• ERD Wells
• Multilateral wells
• Intelligent wells
Gas Lifted wells
SELF FLOWING AND GAS LIFTED WELLS
ELECTRICAL SUBMERISBLE PUMPS (ESP) WELLS
 VERTICAL WELL
30”

20”
DEPTH

13 3/8”
OIL & LI
GAS
LII

GAS SI
2050 PSI 9 5/8”
LIII
1800 psi OIL
1350
PRESSURE 7” LINER
 DIRECTIONAL WELL
30”/26”

20”

13 3/8”

`
LI

LII
9 5/8”
SI

7”
LIII
OIL
HORIZONTAL
WELLS

PRODUCING ZONE

Drain hole
 MULTI-LATERAL WELL
MULTI LATERAL WELL
 FISHBONE MULTI LATERAL WELL

Many ribs branch off the main wellbore. The path of oil to the well is shorter
through a rib than through the rock, both in homogeneous sands and even more in
heterogeneous sands with barriers and baffles. Ribs can be added to any lateral.
WELL MONITORING AND CONTROL
RTU/SCADA
 SCADA – FOR WELL MONITORING, CONTROL AND
PRODUCTION OPTIMIZATION

• SUPERVISORY CONTROL AND DATA ACQUISITION

• Gather necessary DATA from a REMOTELY LOCATED

Oil/Gas well and Well Platform with the help of Field
Transmitters & RTU and send it to the DATA
GATHERING & ANALYSIS point.
 SCADA‐ OVERVIEW

RADIO LINK

LIFT GAS
DATA GATHERING AND
INTERPRETATION
INJECTION WATER

WELL FLUID
WELL PLATFORM PROCESS PLATFORM
 SCADA ‐METHODOLOGY
SSV
OPEN/CLOSE
STATUS
OIL, GAS
WATER
WELL HEAD
FLOW RATES SSV
PRESSURE &
TEMP

GAS/OIL TO GROUP HEADER

GI ACV GAS INJ.

PRESSURE

LIFT GAS FROM

PROCESS
PLATFORM
PARAMETERS AVAILABLE FOR
SSSV LIFT
MEASUREMENT IN AN OIL WELL
OPEN/CLOSE
STATUS PRODUCTION
GAS
RATE
ON GAS LIFT
TUBING

GLV

ANNULUS

BHP

RESERVOIR
 SCADA‐ A SCHEMATIC

ANALOG SIGNALS IN
RANGE OF 1‐5V (4‐20 mA)

MONITORING PRESSURE, TEMP etc AT SAND FACE, RTU INSTALLED ON WELL PLATFORM
WELLHEAD OR ELSEWHERE WITH THE HELP OF SENSORS
(ANALOG TO DIGITAL CONVERSION)

RADIO LINK

INTERFACING SOFTWARE

INTERPRETATION OF STORED DATA DATA GATHERING STATION

(USUALLY A PROCESS PLATFORM)

DECISION MAKING PROCESS

 MAJOR BENEFITS OF SCADA
• 24 hrs online monitoring of well status and flow, lift parameters from
Process Complex as well as from onshore control centre.

• Historical Data and trending helps in Troubleshooting.

• Ability to close wells remotely during emergency.

• Better Production optimization of individual wells

• Instant alerts in case of Well closures, ESD, FSD and control panel failure

• Optimum utilization of Manpower for attending to well problems

• Reduction in number of physical visits to well platforms resulting in

optimization of Helicopter sorties.

• To observe slugging in pipelines.

• Lift gas allocation for each well.

MONITORING OF WELL PLATFORM USING SCADA – THIS IS ACCESSIBLE FROM ANY
DESKTOP COMPUTER IN ONGC LAN NETWORK.

MIMIC DISPLAY
MONITORING OF WELL PLATFORM USING SCADA

STATUS DISPLAY
MONITORING DIFFERENT ALARMS WITH THE HELP OF SCADA
SCADA HELPS IN LIFT GAS ALLOCATION / PRODUCTION ALLOCATION
TRENDING OF GI PRESSURE, MLGIP, TEMPERATURE, LIFT GAS RATE HELPS IN KEEPING
WELLS FLOWING AT ITS OPTIMUM 24x7
WELL AUTOMATION
 DESIGN FOR AUTOMATED CONTROL SYSTEM FOR GL OPTIMIZATION

FLOW SENSORS
FTHP
O W G
PROD.CHOKE

GAS FLOW
REQUIRED FOR
GAS/OIL AUTOMATED OPTIMUM
WHT CONTROL SIGNAL PRODUCTION
ALGORITHM FOR GAS
FEEDBACK
FOR ACV TO LIFT OPTIMIZATION
ADJUST THE LIFT CONTROLER TO
REMOTELY CONTROLLED GI ACV GAS FLOW
(BASED ON GAS‐IN
MAINTAIN THE FIXED
OIL‐OUT CURVE)
LIFT GAS RATE

LIFT GAS FROM PROCESS

PLATFORM

PRODUCTION TUBING
GIP

LIFT GAS
GLV FLOW

ANNULUS

BHP

BHT

RESERVOIR
 Online Monitoring and Remote control of Injection Gas
SP

FLOW COMPUTER
RTU With Flow control card

TT
I/P
RTU

FCV
PT FT TE
GI HEADER

Gas injection to
VB well
CVA
FE

FC is accessed via SCADA from the process complex and

Injection gas Rate is monitored and adjusted, if required,
remotely.
 REMOTE OPTIMIZATION OF WELL USING
SP FC‐MPFM SET
FLOW COMPUTER
RTU With Flow control card

TT
I/P

FCV RTU
PT FT TE
GI HEADER

MPFM
VB Gas injection to
CVA well
FE
WELL
To header

• Injection gas is remotely monitored, controlled via RTU-FC-FCV through SCADA

• One well is diverted via MPFM and Production rates available through SCADA at
Process PF.
• Well can be tested and Optimized REMOTELY for different Injection gas rates by
changing the set point in FC-I/P-FCV Loops via SCADA.
 SMART online 24 x 7 monitoring and Optimization of each well Using
“Gas Flow Computer‐ Compact GLCC Separator‐ Coriolis Mass flow Meter” Set.

GLCC (Gas‐Liquid Cylindrical

Cyclonic) Separator

RTU
(Flow
computer)
Injection Gas
controlled
Remotely through
SCADA by FC‐FCV

Coriolis Mass
Flow Meter

WELL

RTU

To Header
(
Jack up Rig docked in a Wellhead platform
 PROCESSING IN OFFSHORE
PROCESS PLATFORMS

SEA WATER TREATMENT

LIVING QUARTERS
AND INJECTION
GAS COMPRESSION &
DEHYDRATION
SEPARATION AND CRUDE
PUMPING

BRIDGE CONNECTED
WELL PLATFORM
 PROCESSES
3‐Phase well fluid is received from Wells/Well Platforms and processed at
Large Process Platforms generally consisting of the following four Major
Processing Modules

• Separation (Oil, Gas and Produced water) & Oil dispatch

• Gas Compression & dehydration
• Produced Water Conditioning
• Sea water processing & injection system

These process complexes will also have the following:

• Fire detection & Suppression system
• Power Generation
• Well services/drilling Modules
• Water Maker/Utilities/Sewage Treatment
• Living Quarters
SEPARATION
 SEPARATION
• Oil , Gas and Water is separated from the Wellfluid.
• Well Fluid from various Wells/ Well Platforms / Subsea Manifold reaches the process
complex via subsea pipelines and risers and is further processed in more than one
train.
• Each Train will normally consist of a Production Manifold , Well fluid heater, Inlet
Separator, Crude oil Manifold, Crude oil heater, Surge Tanks and MOL Pumps.
• Well Fluid is received in the Production Manifold . Demulsifier Chemical is dozed in
Production manifold to promote breaking up of Water‐Oil emulsion
• Then it is heated in well fluid heater with Hot oil Flowing in Shell Side and well fluid
in tube side. This heating enables better separation of oil and water in Inlet
Separator.
• The Well Fluid from Well fluid heater reaches Inlet Separator.
 Inlet Separator – First Stage Separation
• Inlet Separator is a vessel in which 3 phase separation of well fluid into Oil, Gas and
Water occurs.

• Separation is by gravity mainly assisted by chemical and heat. Residence time in the
vessel is an important criteria for better separation.

• Separated Gas is routed to Gas compression and dehydration Module.

• Compressed gas is sent to the Lift gas network for lifting the producers and excess
gas is exported via pipelines to shore.
• Separated oil flows to the oil manifold.

• Separated water flows to Produced water conditioning unit.

• From oil manifold crude oil flows to crude oil heater in which crude oil is heated with
hot oil. This enhances the separation of oil & water in Surge Tanks (second stage
separation).

• Demulsifier chemical dozed in oil manifold further promotes the breaking of water‐
Oil emulsion.
PFD‐ OIL,GAS,WATER SEPARATION
 Surge Tank – Second Stage Separation
• Surge tank is maintained at a lower pressure to stabilize crude i.e. to
remove maximum of associated gas from the crude oil.

• Oil from surge tanks can be either pumped directly with MOL pumps or
can be diverted to third stage separators (Surge tank‐3).

• Separated crude oil is pumped with CTP / MOL pumps to export trunk
lines.

• Separated Gas is diverted to Gas compression module after boosting the

pressure LP booster compressor.

• Separated Water is diverted to Produced water conditioning Unit.

 Gas For Sales
WELL FROM / TO BHS HP Flare
PLATFORMS
LP Flare

HP Booster Compressors
ZA IU WB
C-1470A C-1470B
LP Flare LP Booster Compressors
FROM / TO BHS
A B
A PB II stage II stage P
Hot oil supply Hot oil supply HP Flare
C-1500A C-1500B
R A B U
From ICG P=8 KSC P=4 KSC I stage I stage
M
O E-1150 E-1280 V-1300
V-1210 O P
D Surge tank TR A
IA WF
Separator TR A
I Crude oil
U TO
Heater Heater
LCV-1304B S
L RESTART LP Flare
C PUMP U
IB
C
T
T
I Skimmer Oil P=2.25 KSC
ID M V-1380 I
O LP Flare
Stabilization tank O
HP Condensate A
N HP Flare N
SG N
Hot oil supply HP Flare
Hot oil supply
P=8 KSC I M
M P=4 KSC
E-1160 V-1220
F A
SM E-1290 V-1310
A Separator TR B
N
WF O Crude oil
Surge tank TR B
N Heater
Heater
I
L TO
SR I LCV-1314B RESTART
F
D PUMP O
F
L
ST
O D
L
From ICD
D To Produced Water
Flesh Vessel
TO

IC
SEPARATION
Oil OF
Processing SUMP

IQ IS SD
OIL/GAS/WATER
WASTE HEAT B
NITROGEN
PCV PSV
Y
RECOVERY ‐ XSDV P
BLANKETING
PCV

Hot Oil System Heat A

Exchanger
Hot oil
S
E‐2810 T=250ºC
Expansion Tank
D
U
C
T=400ºC T catchpot

HIC TIC
281 2814
1 F
I
L
T
E
R
TG Exhaust
F
I
L
Supply Hdr. PIC T
E
PCV R
2853

Return Hdr. TIC

FCV
2850

FIC

TCV‐2881
P
Trim Cooler
E‐2880 P
 TO
TOONSHORE
HEERA
Crude Oil Export
TR A A B

Pump Suction Manifold

TR B

FROM/TO
TR A RECYCLE
LCV-1304 BHS

CTP-1320 CTP-1330 CTP-1340 MOL-1350 MOL-1360 MOL-1370

T/M-1
LCV-1384

T/M-2

LCV-1314
TR A
Discharge Manifold

TR B

TR B RECYCLE TO SURGE
TANKS
CRUDE EVACUATION BY SBM AND TANKER
GAS COMPRESSION, DEHYDRATION
AND EXPORT
 Gas Compression.
• Gas from Separators ,Surge Tanks and export gases if any from other process
platforms are compressed to about 90‐100 kg/cm2 pressure as per the field
gas lift requirement.

• Normally Gas turbine driven Centrifugal compressors (PGC’s‐ Process

Gas Compressors) are used.

• Gases compressed in PGC’s is dehydrated to prevent formation of GAS

HYDRATES. Gas hydrates are formed at low temperatures when moisture is
present in Hydrocarbon gases. These gas hydrates are ice like substance
which prevent the smooth flow or block the flow of gases in gas flow lines.

• Gas Hydrates can be formed in Adjustable Choke Valves ,PCV’s & GLV’s in GI
Lines where Throttling of gases give rise to low temperatures.(Joule
Thomson effect).This can affect production phenomenally from Gas lift wells.
 GAS COLLECTION AND COMPRESSION
Dehydration Manifold

Cooler
Cooler Cooler
Inlet
Manifold

1st Stage 2nd Stage 3rd Stage

K.O.D K.O.D K.O.D
Discharge
K.O.D

Fuel Gas

F H

GG P/T G LP INT HP
M

.
Cond Hdr
 Gas Dehydration
• Compressed Gas is dehydrated in a Glycol contactor with Tri Ethylene
Glycol(TEG)as an absorbent for moisture from compressed gas.

• Glycol contactor is bubble cap tray column with many bubble cap trays. TEG
flows counter current with compressed gas from the top of the column.

• TEG coming in contact with compressed gas in the bubble cap trays
selectively absorbs the moisture from the gas and dehydrates it.

• The dehydrated gas is sent to feed gas lift wells in priority basis and
remaining to export gas line.

• The TEG rich in moisture is sent for re‐concentration , converted to Lean

glycol and recycled back to contactor for dehydration.
 Compressor
Gas Dehydration
Lift Gas
Outlet Mnaifold Net Gas

Lean Glycol/
Gas Exchanger

Coalescer
Separator
Glycol Lean/Rich Glycol
Flash Drum E xchangers Glycol
Tank Contactor Still

F F
F
Glycol
Scrubber
Reboiler

Glycol Storage

Hot Oil
Supply

Circulation Pumps Booster Pumps

Condensate Hdr
Closed Drain Hdr
GAS DEHYDRATION – GAS GLYCOL EXCHANGER
REGENERATION OF GLYCOL
PRODUCED
WATER
TREATMENT
 Produced Water Conditioning
• The water produced along with Oil and Gas from the wells is to be treated to within
acceptable levels of quality in terms of oil ppm before it is discharged in to the sea.

• Produced Water Conditioning unit normally consists of Flash Vessel ,CPI Separators,
IGF (induced Gas floatation Unit) and Sump caisson.

Flash Vessel
Receives water from Both Inlet Separators and Surge tanks .It is maintained at 0.8 kg pressure. In flash Vessel
most of the dissolved gases in the produced water flashes out which is routed to LP flare header. Associated Oil
from the produced water in the flash vessel is routed to closed drain header and is collected in the sump caisson.

CPI separators
Water from the flash vessel flows to many CPI separators (corrugated plate interceptor) in parallel. Oil from CPI
Separator is collected in a tank from which it is pumped to oil manifold. Gas goes to LP Flare header.

IGF unit
•Water from CPI Separator Flows to IGF unit. IGF is a tank in which gas bubbles are aerated with motor driven
agitators. This bubbles float the oil droplets to surface .This collected oil is pumped to CPI separators.

Sump Caisson
Water from IGF is routed to Sump Caisson which is a vessel with bottom end open through which water
continuously drains into the sea. Oil floating in the surface of the sump caisson is collected in the blow caisson
and lifted up and flown into the skimmer with gas injection.
PFD‐ PRODUCED WATER
CONDITIONING
 Produced Water Conditioning
LP Flare

Produced
Water

Flash
Vessel
IGF

CPI Separator

Sump
Caisson

Tank

Surge Tank

Closed Drain
 Skimmer
LP Flare
Feed Gas
Closed Drain

Hot Oil
Supply
Skimmer

Blow
Caisson

Sump
Caisson

Open Drain

Surge Tank
WATER INJECTION
 Water Injection
• Water Injection is done to maintain Reservoir pressure as well as Water flooding.

• To prevent damage to the Reservoir the quality of water injected is strictly complied
with. Also, the health of the pipelines carrying the injection water to the wells and well
platforms is taken care of by dozing chemicals to prevent corrosion and generation of
H2S by SRB colonies.

The Major components of Water Injection systems are:

SEA WATER LIFT PUMPS
COARSE FILTERS
FINE FILTERS
DEOXYGENATION TOWERS
BOOSTERS PUMPS
MAIN INJECTION PUMPS
CHEMICAL DOSING SYSTEM
CHEMICAL DOZING SYSTEM

FLOCCULANT
SCALE INHIBITOR
CORROSION INHIBITIOR
CHLORINATION
BACTERICIDE
OXYGEN SCAVENGER
SEA WATER TREATMENT
FOR WATER INJECTION
 SEA WATER LIFTING AND FILTERING

• Water from sea is Lifted with seawater lift pumps and fed
to Coarse Filters and fine filters for filtering.

• Coarse filters the particles are filtered to 20 microns

• Fine filters the particles are filtered up to 2 microns.

• Poly electrolyte and coagulants are added in sea water lift

pump discharge to promote coagulation of suspended
particles.
 SEA WATER LIFTING ‐ FILTERATION
TO FFIC

FIC FIC FIC FIC FIC

FINE FILTERS
FLOW RATE/FILTER: 425.M3/HR

INLET TEMP:21‐310C
INLET PR: 7KG/CM2

F‐1170 F‐1180 F‐1190 F‐1200 F‐1210 F‐1220 FILTERS UPTO

2 MICRONS

POLYELECTROLYTE

BED LEVEL DRAIN

BED LEVEL DRAIN

BED LEVEL DRAIN

BED LEVEL DRAIN

COAGULANT

BED LEVEL DRAIN

BACKWASH OUT
BED LEVEL DRAIN

BACKWASH OUT

BACKWASH OUT
BACKWASH OUT
BACKWASH OUT
BACKWASH OUT

BACKWASH RATE
MIN::225M3/HR

BACKWASH IN
TO VACCUM PUMPS

BACKWASH IN

BACKWASH IN

BACKWASH IN
BACKWASH IN
BACKWASH IN

MAX:450 M3/HR

FT
DEFOAMER

TO DEOXYGENATION

TO UTILITY WATER HEADER

F‐1110 F‐1120 F‐1130

CHLORINATORS
CH PRODUCTION
MIN:7.0KG/HR
NORMAL:7.0KG/HR FILTERS UPTO
FROM UTILITY WATER HEADER MAX:8.34KG/HR
CH‐1060 CH‐1070 20 MICRONS

COARSE FILTERS
AIR FILTERS M M M

OVER BOARD

CAPACITY:1200 M3/HR
NO.OF SATGES:
MIN.FLOW: 2182M3/HR

DISCH.PR: 7.1KG/CM2
M M MOTOR POWER:460 KW
SPEED:1500 RPM
BLOWERS P‐1010 P‐1020 P‐1030

SEA WATER LIFT PUMPS

 DE‐OXYGYNATION AND PUMPING
• The filtered water flows to Deoxygenating towers for removal of
oxygen.

• Deoxygenation prevents formation of aerobic bacterial colonies(sulfur

reducing bacteria) in the WI flow lines. Vacuum pumps and Oxygen
scavenger chemical dozed facilitates oxygen removal in the towers.

• Booster Pumps take suction from De‐oxygenation Towers and feed

Main Injection Pumps.

• Scale inhibitors, Bactericide and corrosion inhibitor chemicals are

dozed in the discharge of booster pumps.

• MIP’s discharge the treated water to Water Injection subsea pipelines

to wells and well platforms for injecting in to water injection Wells.
 DEOXYGENATION TOWER TR‐A
AIR FILTERS
DE‐OXYGYNATION AND INJECTION
FIC

VACCUM PUMPS
EJECTOR CAPACITY: 1129.5 M3/HR
M‐1320
NORMAL: 982.2 5 M3/HR
AIR RATING:28.2KG/HR P‐1350

DEOXYGENTION
CAPACITY:851M3/HR
M SEPARATOR
OXYGEN CONTENT OF
P‐1360
TREATED WATER:0.02MG/LIT

OXYGEN SCAVENGER
FFIC
M

LIC SEAL WATER XSPL

OVER BOARD

CORROSION INHIBITOR
SCALE INHIBITOR‐II
PIC

SCALE INHIBITOR‐I
MAIN INJECTION PUMPS

BACTERIOCIDE‐I

BACTERIOCIDE‐II
OVER BOARD

CAPACITY: 415 M3/HR

DEOXYGENATION TOWER TR‐B MOTOR POWER: 2250 KW
MINIMUM SPEED:
FLOW: 103 3/HR
2985MRPM
AIR FILTERS P: 134.7 KG/CM2
FIC

CAPACITY: 851 M3/HR P‐1610

HCV
DEOXYGENTION
EJECTOR
SEPARATOR
MOTOR POWER: 322 KW
M‐1420 M SPEED:212
MINIMUM FLOW: M3RPM
1480 /HR
P: 10 KG/CM2 PCV
P‐1510
P‐1450
BOOSTER PUMPS

L‐1660
P‐1620

L‐1680
OVER BOARD
M
P‐1460
CORROSION INHIBITOR

M
SCALE INHIBITOR‐II
SCALE INHIBITOR‐I

P‐1520
BACTERIOCIDE‐I

BACTERIOCIDE‐II
OXYGEN SCAVENGER P‐1630

M
VACCUM PUMPS
SEAL WATER

LIC

OVER BOARD HCV

P‐1640
PCV
M PIC SE WI‐11 SP
P‐1530

OVER BOARD OVER BOARD

P‐1650
XSPL
 Fire Detection & Suppression System

Detection System Suppression System

• Gas Detection • FIRE WATER PUMPS

• Water Sprinkler
• Fusible Plug
• Dry Chemical
• Fire Detection • FM‐200
• Smoke Detection • CO2 Extinguisher
• Heat Detection • AFFF SYSTEM

Escape / Abandon
• Escape Ladder
• Scramble Net
• Life Ring
• Life Raft
• Life Boat
• Jumping Rope 91
 UTILITIES
• POWER GENEARTION – GAS TURBINE DRIVEN GEBERATORS
• WATER MAKERS‐ RO WATER MAKERS
• LIVING QUARTERS AND ASSOCIATED REQUIREMNETS LIKE
LAUNDRY, GALLEY
• EMERGENCY DIESEL GENERATORS
• COMMUNICATION SYSTEMS
SEWAGE TREATMENT
 NEW TECHNOLOGIES
Intelligent wells
DIGITAL OIL FIELD
MULTIPHASE PUMPING
SUBSEA SEPARATION AND RE‐INJECTION
GAS TO WIRE
 Intelligent Wells
Wells Equipped at Completion with Downhole Controls
and Sensors

Horizontal
producer
Proactive Pilot well Gas Injector
Remediation of
Fluid Inflow

z Remote controlled
Downhole zonal
control valves
z Implement
reservoir
decisions without
intervention Continuous data from wells
Pressure Inflow Flowing
• Optical Pressure Gauge Performance Distribution Phase
• Optical Distributed Temperature Gauge.
• Data is transmitted up the wellbore via fibre
Downhole Reservoir
optics. Seismic Saturation
 DIGITAL OILFIELD
Data Store
HIVE

Real-time Data
Transmission

Decision
Facilities Driven
Facilities
Integration for model Analysis
Business
Decisions model
Reservoir
4D/4C - Permanent model
A high‐resoluble data is obtainable by a 4C seismic
seismic
survey using 4 components OBC ( marine earthquake
Control,
cable ) with a hydrophone and 3 geophone components. Optimisation &
Intervention Market
Drivers &
intelligence
Export/Transport
Reservoir
Management

Well Construction
Intelligent Wells e-business
 MULTI PHASE PUMPING
Multiphase production systems require the transportation of a mixture of oil, water and
gas, often for many miles from the producing well to a distant processing facility.

This represents a significant departure from conventional production operations in which

fluids are separated before being pumped and compressed through separate pipelines. By
eliminating this equipment, the cost of a multiphase pumping facility is about 70% that
of a conventional facility and significantly more savings can be realized if the need for
an offshore structure is eliminated altogether.

However, multiphase pumps do operate less efficiently (30-50%, depending on Gas

volume fraction and other factors) than conventional pumps (60- 70%) and compressors
(70-90%).

Still, a number of advantages in using multiphase pumps can be realized, including:

1)Increased production through lowering backpressure on wells;
2)Elimination of vapor recovery systems;
3)Reduced permitting needs;
4)Reduction in capital equipment costs; and,
5)Reduction in “footprint” of operations .
 CONVENTIONAL AND
MULTIPHASE PUMPING
z Multiphase pumping is a relatively new
technology and acceptance has been hampered
by a lack of engineering design tools.
z Recently, pipeline simulation codes have
incorporated the ability to model multiphase
pump performance as part of the overall
multiphase production system
 SUBSEA PROCESSING
• Normally used in deepwater

• Separation of heavy oil and water

• Reinjection of water to boost production in a mature field

development.

• The separation system may also includes cyclone modules that will
perform water treatment before reinjection the water back into the
reservoir.

"a true subsea development is very environmentally friendly."

THANKS