Process Engineering for Non-Process
Prepared by: Suliana Suliman
Date: 4th October 2018
Topics:
• Oil and Gas Segment
• Production
• Processing
• Piping & Instrumentation Diagram (P&ID)
• Pipe Classification
• Valve Selection
• Insulation
• Separation
• Instrumentation
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Oil and Gas Segment
Exploration& Field Production Transportation
Transportation & Refining Distribution
Extraction Production & Processing
Appraisal Development Storage to user
• Separation Recycle
• Find the field • To meet product • Pipeline • Refined
• Wells are
spec. products
drilled
• Well appraisal • Tanker
• Wellhead Gas Compression
• Seismic survey Reservoir • Crude Oil Terminal
Platform
• Feasibility study
Wellhead Flare
facilities
Full Well Oil Stabilization
Stream (FWS)
Water
Treatment -
overboard
UPSTREAM MIDTREAM DOWNSTREAM
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Production
Wellhead Platform
• Where facilities (onshore and offshore) take the oil &
gas mixture out of the wells
• Producer wells (Oil / Gas)
• Injector wells (Gas/ Water) - enhanced oil recovery
• Single / Dual Completion
• Gas lift
• Production / Test Header
• Well Testing - Test Separator
• Utilities: Instrument Air, Open & Closed Drain,
Firewater, etc.
• Examples: GuB, GuC, PaA
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Gas Lift Gas Injection
1. Inject into oil producer wells tubing 1. Has its own wellhead
2. To lift the well fluids by reduce the 2. To maintain oil reservoir pressure
fluid’s density
• Pressure Equalization Line:
early life of wells (high pressure)
Introduce pressure downstream of choke valve, SSV
and SCSSV before valves opening (prevent valve
damage)
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Process Flow Diagram (PFD)
• Overview / general flow of processes and equipment – main lines & equipment
• Show relationship between major equipment
• Does not show minor details such as piping details
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Heat & Material Balance (HMB)
• Tabulate operating conditions and
properties
• Need to cross-referred with PFD/UFD
• Reference for datasheet and calculation
• Results from HYSYS simulation
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Oil Producer – Single Completion
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Water Injector – Single Completion
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Processing
Central Processing Platform
• Further process to meet product (oil / gas)
specification
• Crude Stabilization – multi-stages separation
• Gas Compression – for gas injection / gas lift
• Produced Water Treatment – before overboard
• Utilities: Instrument Air, Open & Closed Drain,
Firewater, Diesel, Chemical Inject.
• Examples: GuA, GuD
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Crude Stabilization System - PFD
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Gas Compression System - PFD
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Produced Water Treatment - PFD
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Piping & Instrumentation Diagram
(P&ID)
• Also known: Mechanical Flow Diagram (MFD)
• Detail diagram, which shows:
a) Piping and its details (line no., spec, service)
b) Equipment (design condition, dimension, etc.)
c) Instrumentation (safety & control devices)
d) Isolation valves
e) Miscellaneous: vent and drain lines, liquid level diagram, spec. break
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Pipe Classification
1. Pressure rating (150#/300#/600#, etc):
• How to select the rating: See the source of pressure (i.e. equipment)
• Select the pressure rating higher than the design pressure of the
equipment
• Can be fully rated or lower
• When de-rate, PSV is required on the lower system for overpressure
protection
2. Pipe material:
• Based on service / fluid flowing in the pipe
• Also consider max / min. design metal temp. (i.e. low temp. CS)
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Valve Selection
1. Block valve:
• For isolation, on-off valve
• Ball, gate
• Provide at inlet and outlet of equipment
• Require full bore (FB) at inlet outlet of PSVs, inlet of Launcher /
Receiver.
2. Throttling valve:
• For regulating
• Globe, butterfly
• Provide at drain line, bypass of control valve
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Insulation
1. Purposes:
• For personnel protection
• For heat conservation (hot or cold)
• For acoustic insulation
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Separation (Two / Three Phase)
Two Phase Three Phase
1. Separate into liq. (oil + water) and gas 1. Separate into oil + water + gas
`
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Instrumentation
1. Real time measurement, control and safety
2. To meet safety, environmental regulations, quality and productivity
3. Process variables: Pressure, Temperature, Level, Flowrate
4. Measurement / monitoring: meter, gauge
5. Control: Control Valve, regulator
6. Safety: PSV, SDV, BDV
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