Upload
abhinav-gupta
View
217
Download
0
Embed Size (px)
Citation preview
7/28/2019 Copy of IEMR-CEST-Oil Production
1/44
Oil and Gas Production
7/28/2019 Copy of IEMR-CEST-Oil Production
2/44
Oil and Gas Industry Overview (UPSTREAM)
Source: Methane to Markets, Oil & Gas Industry Overview
7/28/2019 Copy of IEMR-CEST-Oil Production
3/44
Production Flow Diagram
Source: Oil & Gas Production Handbook , ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
4/44
Separation
7/28/2019 Copy of IEMR-CEST-Oil Production
5/44
WELL FLUIDS & WELL CLASSIFICATION
Wells are generally classified according to the type of fluid they produce in
the greatest quantity.
CLASS OF WELLFLUIDS IN
RESERVOIR
FLUIDS IN FLOW
LINE
PROCESSING STEPS
WHICH MAY BE
REQUIRED
DRY GASGAS, POSSIBLY
WATER
GAS, POSSIBLY
WATER
SEPARATION, GAS
DEHYDRATION
GAS CONDENSATEGAS, POSSIBLY
WATER
GAS CONDENSATE,
POSSIBLY WATER
SEPARATION, GAS &
CONDENSATE
DEHYDRATION
CRUDE OIL
CRUDE OIL,
POSSIBLY GAS
POSSIBLY WATER
CRUDE OIL,
POSSIBLY GAS,
POSSIBLY WATER
SEPARATION, GAS
DEHYDRATION
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
6/44
Reservoir pressures are generally much higher than atmospheric pressure. As well
fluids reach the surface, pressure on them is decreased. The liquid ability to hold gas
in solution decreases, and the liquids begin to release 'Solution Gas'.
In summary, there are variables which aid in the separation of a fluid stream.
Temperature of the fluids.
Pressure on the fluids.
Density of the components.
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
7/44
Separator
A SEPARATOR is a vessel in which a mixture of immiscible fluids are separated;
e.g. Crude oil, Natural gas and Water. A separator may be a 'Horizontal', 'Vertical'
or 'Spherical' vessel.
Fluid flow from a well can include gas, free water, condensable vapours (water or
hydrocarbons), crude oil, and solid debris (basic sediment). The proportion of
each component varies in different well streams.
Although most separators are two -phase in design, separating the gas and total
liquids, three - phase vessels can be built to separate natural gas, oil or other
liquid hydrocarbons, and free water.
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
8/44
SEPARATOR FUNCTIONS
A well stream separator must perform the following:
Cause a primary phase separation of the liquid hydrocarbon from those that are
Gas.
Refine the primary separation by removing most of the entrained liquid mist from
the gas.
Further refine the separation by removing the entrained gas from the liquid.
Discharge the separated gas and liquid from the vessel and ensure that no re-
entrainment of one into the other takes place.
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
9/44
The main principles used to achieve physical separation of gas and liquids
are: GRAVITY SETTLING and COALESCING
Any separator may employ one or more of these principles, but the fluid phases must
be 'Immiscible' (cannot mix), and have 'Different Densities' for separation to occur
Separation vessels usually contain four major sections, plus the necessary pressure
and liquid level controls. These sections are:1. Primary Separation Section
2. Secondary Separation Section
3. Mist Extraction Section
4. Liquid Accumulation Section
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
10/44
TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Vertical
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
11/44
TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Horizontal
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
12/44
TYPES OF SEPARATOR
GAS / LIQUID SEPARATORS- Tangential or Cyclone
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
13/44
TYPES OF SEPARATOR
LIQUID / LIQUID SEPARATORS- Coalescer
Source: http://articles.compressionjobs.com/articles/oilfield
http://articles.compressionjobs.com/articles/oilfieldhttp://articles.compressionjobs.com/articles/oilfield7/28/2019 Copy of IEMR-CEST-Oil Production
14/44
Separation
Test Separators and Well test
Production separators (First Stage)
Second stage separator
Third stage separator
Coalescer
Electrostatic Desalter
Water treatment
Source: Oil & Gas Production Handbook , ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
15/44
Gas Treatment and Compression
7/28/2019 Copy of IEMR-CEST-Oil Production
16/44
HEAT EXCHANGER
Heat transferis a process by which internal energy
from one substance transfers to another substance.
Usually from a body at higher temperature to a body
at lower temperature.
Source: Wikipedia
7/28/2019 Copy of IEMR-CEST-Oil Production
17/44
Modes of Heat Transfer
Conduction
Convection
Radiation
Source: Wikipedia
7/28/2019 Copy of IEMR-CEST-Oil Production
18/44
Heat exchangers are devices used to transfer heat energy from one fluid to another.
Types of Heat Exchangers: Shell and Tube
Plate Type
Double Pipe
Spiral
Regenerative
Source: http://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdf
http://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdfhttp://nptel.iitm.ac.in/courses/Webcourse-contents/IISc-BANG/Heat%20and%20Mass%20Transfer/pdf/M7/Student_Slides_M7.pdf7/28/2019 Copy of IEMR-CEST-Oil Production
19/44
SHELL AND TUBE HEAT EXCHANGER
It is the most common type of heat exchanger in oil refineries and other large
chemical processes
Suited for higher-pressure applications.
As its name implies, this type of heat exchanger consists of a shell (a
large pressure vessel) with a bundle of tubes inside it.
One fluid runs through the tubes, and another fluid flows over the tubes (through
the shell) to transfer heat between the two fluids.
The set of tubes is called a tube bundle, and may be composed by several types
of tubes: plain, longitudinally finned, etc.
Source: http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx
http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx7/28/2019 Copy of IEMR-CEST-Oil Production
20/44
Source: http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx
http://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspxhttp://www.doyouknow.in/Articles/Engineering/Shell-And-Tube-Heat-Exchanger.aspx7/28/2019 Copy of IEMR-CEST-Oil Production
21/44
Tube Bundle
Source: Heat Exchangers, Types and ApplicationsCairo University, Faculty of Engineering, Chemical Engineering Department
7/28/2019 Copy of IEMR-CEST-Oil Production
22/44
Baffle Arrangement
Source: Heat Exchangers, Types and ApplicationsCairo University, Faculty of Engineering, Chemical Engineering Department
7/28/2019 Copy of IEMR-CEST-Oil Production
23/44
Source: http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/
http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/http://heatexchanger-design.com/2011/04/28/oil-heat-exchanger-4/7/28/2019 Copy of IEMR-CEST-Oil Production
24/44
PLATE AND FRAME HEAT EXCHANGER
A plate type heat exchanger, consists of plates instead of tubes to separate the hot
and cold fluids. The hot and cold fluids alternate between each of the plates.
Baffles direct the flow of fluid between plates. Because each of the plates has a
very large surface area, the plates provide each of the fluids with an extremely
large heat transfer area.
Therefore a plate type heat exchanger, as compared to a similarly sized tube
and shell heat exchanger, is capable of transferring much more heat. This is due tothe larger area the plates provide over tubes.
Due to the high heat transfer efficiency of the plates, plate type heat
exchangers are usually very small when compared to a tube and shell type heat
exchanger with the same heat transfer capacity.
Plate type heat exchangers are not widely used because of the inability to reliably
seal the large gaskets between each of the plates.
Because of this problem, plate type heat exchangers have only been used in small,
low pressure applications such as on oil coolers for engines. However, new
improvements in gasket design and overall heat exchanger design have allowed
some large scale applications of the plate type heat exchanger
Source: http://www.engineersedge.com/heat_exchanger/plate.htm
http://www.engineersedge.com/heat_exchanger/plate.htmhttp://www.engineersedge.com/heat_exchanger/plate.htm7/28/2019 Copy of IEMR-CEST-Oil Production
25/44
Source: http://www.engineersedge.com/heat_exchanger/plate.htm
http://www.engineersedge.com/heat_exchanger/plate.htmhttp://www.engineersedge.com/heat_exchanger/plate.htm7/28/2019 Copy of IEMR-CEST-Oil Production
26/44
Source: Heat Exchangers, Types and ApplicationsCairo University, Faculty of Engineering, Chemical Engineering Department
7/28/2019 Copy of IEMR-CEST-Oil Production
27/44
Source: Heat Exchangers, Types and ApplicationsCairo University, Faculty of Engineering, Chemical Engineering Department
7/28/2019 Copy of IEMR-CEST-Oil Production
28/44
Source: Heat Exchangers, Types and Applications
Cairo University, Faculty of Engineering, Chemical Engineering Department
7/28/2019 Copy of IEMR-CEST-Oil Production
29/44
SCRUBBERS & REBOILERS
Source: Oil and Gas Production Handbook, ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
30/44
COMPRESSORS
A gas compressoris a mechanical device that increases the pressure of a gas by
reducing its volume.
Compressors are driven by gas turbines or electrical motors (for lower power also
reciprocating engines, steam turbines are sometimes used if thermal energy is
available). Often several stages in the same train are driven by the same motor or
turbine
Source: http://en.wikipedia.org/wiki/Gas_compressor
TYPES OF COMPRESSORS
http://en.wikipedia.org/wiki/Gas_compressorhttp://en.wikipedia.org/wiki/Gas_compressor7/28/2019 Copy of IEMR-CEST-Oil Production
31/44
TYPES OF COMPRESSORS
PARAMETERS RECIPROCATING
COMPRESSORS
SCREW
COMPRESSORS
AXIAL BLADE
COMPRESSORS
CENTRIFUGAL
COMPRESSORS
Build A piston and cylinderdesign with 2-2
cylinders
Two counterrotating screws
with matching
profiles provide
positive
displacement and a
wide operating
range.
Axial blade and fintype Compressors
with up to 15
wheels provide
high volumes at
relatively low
pressure
differential
(discharge pressure
3-5 times inlet
pressure)
Centrifugalcompressors
with 3-10 radial
wheels, Pressure
differential up to 10.
Power (MW) 30 MW up to several MW Upto 80 MW
Synchronous Speed
(rpm)
500-800 3000/3600 5000-8000 6000 20000
(highest
for small size)
Pressure 5 MPa 2.5 MPA (25 bars) Upto 50 bars
Used for Lower capacity gas
compression and high
reservoir pressure gas
injection
Typical use is
natural gas
gathering.
Air compressors
and cooling
compression in
LNG plants
Larger oil and gas
installations
Source: Oil and Gas Production Handbook, ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
32/44
Reciprocating Compressor Screw Compressors
Source: Oil and Gas Production Handbook, ABB
Axial Blade CompressorsCentrifugal Compressors
7/28/2019 Copy of IEMR-CEST-Oil Production
33/44
Performance Control
The object of the compressor performance controlis to keep the operating point
close to the optimal set pointwithout violating the constraints, by means ofcontrol outputs, such as the speed setting.
However gas turbine speed control response is relatively slow and even electrical
motors are not fast enough since the surge response must be in the 100 mS range.
The anti surge control will protect the compressor from going into surge by
operating the surge control valve.
Basic strategy: to use distance between operating point and surge line to control
the valve with a slower response time starting at the surge control line. Crossing
the surge trip line will control a fast response opening of the surge valve to protect
the compressor.
Compressor maintenance intensive:
Load management Vibration
Speed governor
Source: Oil and Gas Production Handbook, ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
34/44
Chemical & Additives
Wide range of chemicals used in various processes in production of crude oil.
Scale Inhibitors:
Well flow contains Contaminants like Salt, chalk, traces of radioactive elements
precipitates due to the change in temperature and pressure and get stuck or clog
up in the pipes, heat exchangers, values.
Helps in preventing the contaminants spreading out. Added on well heads &
production equipments.
Emulsion Breaker :
The layer formed between oil and water is emulsion. We need to separate bothand extract oil. Added to prevent the formation and breakdown of emulsion layer.
Sand and other particles will be absorbed by water.
Sources : Oil & gas handbook production ABB, Wikipedia
7/28/2019 Copy of IEMR-CEST-Oil Production
35/44
Antifoam :Foam is produced in the separator .This foam will cover the fluid surface and block the gas to
escape, reduces the gas space inside the separator. Escapes through demister as mists & vapors.Antifoam agent introduced in the upstream of separator to prevent or break down foam
formation.
Source :Oil & gas Handbook ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
36/44
Methanol : Injected in flow lines to prevent hydrates formation and corrosion
Hydrates are crystalline compounds that form in water crystalline structures as afunction of composition, temperature and pressure.
Hydrates might form and freeze forming hydrate ice, that may damage pipes andequipments.
Hydrates prediction model software can be used to determine when there is a risk ofhydrate formation or to reduce methanol injection or delay pressurization
Drag Reducers : In pipe lines oil flow near the pipe will be less and the flow at centre will be high
,causing turbulent bursts resulting turbulent eddies.
drag reduction polymers suppress the turbulent bursts, which improves flow inpipelines.
Sources : Oil & gas handbook production ABB, Wikipedia
7/28/2019 Copy of IEMR-CEST-Oil Production
37/44
GAS TREATMENT
When the gas is exported, many gas trains include additional equipment for
further gas processing, to remove unwanted components such as hydrogen sulfide
and carbon dioxide. These gases are called acids and sweetening /acid removal is
the process of taking them out.
Natural gas sweetening methods include absorption processes, cryogenic
processes; adsorption processes and membranes. Often hybrid combinations areused, such as cryogenic and membranes.
Source: Oil and Gas Production Handbook, ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
38/44
Oil & Gas Storage, Metering and
Export
7/28/2019 Copy of IEMR-CEST-Oil Production
39/44
Oil and Gas Storage, Metering and
Export
The final stage before the oil and gas leaves the platform consists of
storage, pumps and pipeline terminal equipment.
7/28/2019 Copy of IEMR-CEST-Oil Production
40/44
Oil and Gas Metering
Fiscal Metering
Partners, authorities and customers all calculate invoices, taxes and payments
based on the actual product shipped out.
Often custody transfer also takes place at this point, means a transfer of
responsibility or title from the producer to a customer, shuttle tanker
operator or pipeline operator.
Sources: Oil and gas production handbook; ABBhttp://www.standard.no/PageFiles/1224/I-SR-104r1.pdf
7/28/2019 Copy of IEMR-CEST-Oil Production
41/44
Metering System Contd.
Analyzer
The analyser instruments provides product data such as density, viscosity
and water content. Pressure and temperature measurement is also
included.
For liquid, turbine meters with dual pulse outputs are most common The metering is split into several runs, and the number of runs in use
depends on the flow.
Each run employs one meter and several instruments to provide
temperature and pressure correction Open/Close valves allow runs to be
selected and control valves can balance the flow between runs.
Sources: Oil and gas production handbook; ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
42/44
Metering System
Sources: Oil and gas production handbook; ABB
htt ://instrumenttoolbox.blo s ot.com/2011/05/how-to-construct-instrument.html
7/28/2019 Copy of IEMR-CEST-Oil Production
43/44
Gas metering
Gas metering is similar, but instead, analysers will measure
hydrocarbon content and energy value (MJ/scm or BTU, Kcal/scf) aswell as pressure and temperature.
The meters are normally orifice meters or ultrasonic meters. Different
ranges are accommodated with different size restrictions.
The pressure differential over the orifice plate as well as pressure and
temperature is used in standard formulas to calculate normalized flow.
Larger new installations therefore prefer ultrasonic gas meters that
work by sending multiple ultrasonic beams across the path and
measure the Doppler Effect.
Sources: Oil and gas production handbook; ABB
7/28/2019 Copy of IEMR-CEST-Oil Production
44/44
LNG metering
LNG is often metered with massflow meters that can operate at the
required low temperature.
However recently Ultrasonic flow meters are being used, which offer
the right technology and value proposition for custody-transfer
applications.