ABB Oil Gas production Hand Book.pdf

OIL AND GAS

PRODUCTION

HANDBOOK

An introduction to oil and gas production

Håvard Devold

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PREFACE

This handbook is has been compiled to give readers with an interested in the oil and

gas production industry an overview of the main processes and equipment. When I

started to search for a suitable introduction to be used for new engineers, I

discovered that much of this equipment is described in standards, equipment manuals

and project documentation. But little material was found to quickly give the reader

an overview of the entire upstream area, while still preserving enough detail to let the

engineer get an appreciation of the main characteristics and design issues.,

This book is by no means a comprehensive description on the detailed design of any

part of this process, and many details have been omitted in the interest of overview. I

have included some comments on the control issues, since that is part of my own

background. For the same reason, the description will be somewhat biased toward

the offshore installations.

The material has been compiled form various online sources as well as ABB and

customer documents. I am thankful to my colleagues in the industry for providing

valuable input, in particular Erik Solbu of Norsk Hydro for the Njord process and

valuable comments. I have included many photos to give the reader an impression

what typical facilities or equipment look like. Non-ABB photo source given below

picture other pictures and illustrations are ABB.

Edition 1.3 Oslo, June 2006

Håvard Devold

Except as otherwise indicated, all materials, including but not limited to design, text, graphics,

other files, and the selection and arrangement thereof, are the copyright property of ABB, ALL

RIGHTS RESERVED. You may electronically copy and print hard-copy of this document only for

non-commercial personal use, or non-commercial use within the organization that employs you,

provided that the materials are not modified and all copyright or proprietary notices are retained.

Use of photos and graphics and references form other sources in no way promotes or endorses

these products and services and is for illustration only.

CONTENTS

1 Introduction....................................................................................................... 4

2 Process overview .............................................................................................. 6

2.1 Facilities .................................................................................................. 7

2.1.1 Onshore.......................................................................................... 8

2.1.2 Offshore ......................................................................................... 9

2.2 Main Process Sections........................................................................... 12

2.2.1 Wellheads .................................................................................... 12

2.2.2 Manifolds/gathering..................................................................... 12

2.2.3 Separation .................................................................................... 13

2.2.4 Gas compression .......................................................................... 14

2.2.5 Metering, storage and export ....................................................... 15

2.3 Utility systems....................................................................................... 16

3 Reservoir and Wellheads ................................................................................ 17

3.1 Crude oil and Natural gas ...................................................................... 17

3.1.1 Crude Oil ..................................................................................... 17

3.1.2 Natural Gas .................................................................................. 18

3.1.3 Condensates ................................................................................. 19

3.2 The Reservoir ........................................................................................ 19

3.3 Exploration and Drilling........................................................................ 21

3.4 The Well................................................................................................ 24

3.4.1 Well Casing ................................................................................. 25

3.4.2 Completion .................................................................................. 26

3.5 Wellhead ............................................................................................... 27

3.5.1 Subsea wells ................................................................................ 29

3.5.2 Injection ....................................................................................... 30

3.6 Artificial Lift ......................................................................................... 30

3.6.1 Rod Pumps................................................................................... 31

3.6.2 Downhole Pumps......................................................................... 31

3.6.3 Gas Lift ........................................................................................ 32

3.6.4 Plunger Lift .................................................................................. 33

3.7 Well workover, intervention and stimulation. ....................................... 33

3.8 Unconventional sources of oil and gas .................................................. 35

3.8.1 Extra Heavy Crude ...................................................................... 35

3.8.2 Tar sands...................................................................................... 36

3.8.3 Oil Shale ...................................................................................... 36

3.8.4 Coal, Coal Gasification and Liquefaction.................................... 37

3.8.5 Methane Hydrates ........................................................................ 37

3.8.6 Biofuels........................................................................................ 38

3.8.7 Hydrogen ..................................................................................... 38

4 The Oil and Gas Process ................................................................................. 40

4.1

Manifolds and Gathering....................................................................... 42

4.1.1 Pipelines, and Risers .................................................................... 42

4.1.2 Production, test and injection manifolds...................................... 42

4.2 Separation.............................................................................................. 43

4.2.1 Test Separators and Well test....................................................... 43

4.2.2 Production separators................................................................... 43

4.2.3 Second stage separator................................................................. 45

4.2.4 Third stage separator.................................................................... 45

4.2.5 Coalescer ..................................................................................... 46

4.2.6 Electrostatic Desalter ................................................................... 46

4.2.7 Water treatment ........................................................................... 46

4.3 Gas treatment and Compression............................................................ 48

4.3.1 Heat exchangers........................................................................... 48

4.3.2 Scrubbers and reboilers................................................................ 49

4.3.3 Compressor anti surge and performance...................................... 50

4.3.4 Gas Treatment.............................................................................. 54

4.4 Oil and Gas Storage, Metering and Export ........................................... 54

4.4.1 Fiscal Metering ............................................................................ 54

4.4.2 Storage ......................................................................................... 57

4.4.3 Marine Loading ........................................................................... 58

4.4.4 Pipeline terminal .......................................................................... 58

5 Utility systems ................................................................................................ 59

5.1 Control and Safety Systems .................................................................. 59

5.1.1 Process Control ............................................................................ 59

5.1.2 Emergency Shutdown and Process Shutdown ............................. 62

5.1.3 Control and Safety configuration................................................. 63

5.1.4 Fire and Gas Systems................................................................... 65

5.1.5 Telemetry / SCADA .................................................................... 66

5.1.6 Condition Monitoring and Maintenance Support ........................ 67

5.1.7 Production Information Management Systems (PIMS) ............... 68

5.1.8 Training Simulators ..................................................................... 69

5.2 Power generation and distribution......................................................... 69

5.3 Flare and Atmospheric Ventilation ....................................................... 71

5.4 Instrument air ........................................................................................ 72

5.5 HVAC ................................................................................................... 72

5.6 Water Systems....................................................................................... 73

5.6.1 Potable Water............................................................................... 73

5.6.2 Seawater....................................................................................... 73

5.6.3 Ballast Water ............................................................................... 73

5.7 Chemicals and Additives....................................................................... 74

5.8 Telecom................................................................................................. 77

6 Units................................................................................................................ 78

7 Acronyms........................................................................................................ 80

8 References....................................................................................................... 82

1 Introduction

Oil has been used for lighting purposes for many thousand years. In areas where oil

is found in shallow reservoirs, seeps of crude oil or gas may naturally develop, and

some oil could simply be collected from seepage or tar ponds. Historically, we know

of tales of eternal fires where oil and gas seeps would ignite and burn. One example

1000 B.C. is the site where the famous oracle of Delphi would be built, and 500 B.C.

Chinese were using natural gas to boil water.

But it was not until 1859 that "Colonel" Edwin Drake drilled the first successful oil

well, for the sole purpose of finding oil.

The Drake Well was located in the middle of quiet farm country in north-western

Pennsylvania, and began the international search for and industrial use of petroleum.

Photo: Drake Well Museum Collection, Titusville, PA

These wells were shallow by modern standards, often less than 50 meters, but could

give quite large production. In the picture from the Tarr Farm, Oil Creek Valley, the

Phillips well on the right was flowing initially at 4000 barrels per day in October

1861, and the Woodford well on the left came in at 1500 barrels per day in July,

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