CE4105

Surface Production Operations

Operasi Produksi Permukaan Hidrokarbon / Operasi Hulu Minyak dan Gas

Rinaldi M Rachman S.T., M.S.

 Schedule & Rules
CLASS HOURS CE1
Mon: 3-5 PM at 2806
Wed: 9-10 AM at 2407

OFFICE HOURS
Griya Legita, L2, by appointment

COURSE CONTRACT

CE4105 Surface Production Operations

 Schedule & Rules
CLASS HOURS CE2
Tue: 9-11 AM at 2102
Fri: 1-2 PM at 2401

OFFICE HOURS
Griya Legita, L2, by appointment

COURSE CONTRACT

CE4105 Surface Production Operations

 Grading & Exams
Evaluation Weight
Quiz(es) 20%
Assignment(s) 20%

Midterm 30%
Final Exam* 30%

* Minimum class attendance: 80%

CE4105 Surface Production Operations

 Recommended References
1. Arnold Ken, Stewart Maurice. “Surface Production Operations Vol.1&2,” 3rd Ed. Elsevier Science
Publishers B.V., Amsterdam.
2. Chilingarian, Robertson, Kumar. 1989. “Suface Operation in Petroleum Production, vol I and II.”
Elsevier Science Publishers B.V., Amsterdam.

CE4105 Surface Production Operations

 Class Outline
Week# Description
1 Intro to Surface Operation and Production Facilities, Types of Reservoir Fluids, Concept of GOR, GOL

2 Selection processes: control system, system configurations, well testing, gas lifting, offshore vs onshore

3 Two phase separation: oil and gas

4 Three phase separation: oil, water, and emulsion

5 Crude oil treating system

6 Produced water treating system

7 Assignment: Two-phase separator design & Oral Presentation

CE4105 Surface Production Operations

 CE4105
Surface Production Operations
Lecture 1
INTRODUCTION TO SURFACE PRODUCTION OPERATIONS

Learning Outcomes:
1. Understand the overall surface production operations flow
2. Differentiate types of fluid reservoir
3. Understand the concept of GOR (gas to oil ratio)
 CE4105 Surface Production Operations

General Overview
§ An OIL FIELD usually produces oil from several wells, which generally produce well stream fluids containing a
mixture of oil, gas, and water

§ The main process of oil and gas production facility is to seperate the well stream into three components, namely
oil, gas, and water. Then process these components into some marketable products or dispose of them in an
environmentally acceptable manner

§ In mechanical devices (separators) gas is flashed from the liquids and free water is sepereated from the oil.
Theses processes remove light HC to produce a stable crude oil with the volatility (vapor pressure) to meet
market criteria.

§ The seperated gas must be compresses and treated for sales. Compression is typically carried out by engine-
driven reciprocating compressors. In large facilities or booster series, turbine-driven centrifugal compressors are
used. The saturated gas is treated (dehydrated) to remove the water vapor in glycol dehydrator.
 CE4105 Surface Production Operations

Overall Schematic of Oil & Gas Field

LNG C1, C2
§ GAS FIELD
LPG C3, C4
Natural Gas Oil – Gas
Gas Field Natural Gas
(Non-associated) Separation

Heavy NGL C5+

LNG C1, C2
associated Gas
§ OIL FIELD gas LPG C3, C4
processing
Natural Gas
Oil Field

Light NGL C5-C7

Crude Off-gas/LPG C3, C4 Light

Oil Refinery
Oil (C5-C6)
Naphtha C5-C9
Heavy
C10-C20 (C6-C9)
raw material for up-stream petrochemical industy Gas-oil
 CE4105 Surface Production Operations

Oil Well
Associated gas

Separator Vent gas

Stock
Tank
Oil

Dari sumur
Reservoir
P, T, V
 CE4105 Surface Production Operations

Oil Field Production System

Scrubber
Compressor Glycol

Separator
dehydrator

Oil treater

Disposal well

Coalescer
 CE4105 Surface Production Operations

Gas Field Production System

Sales gas

C1/C2

Fractionation Plant Offshore

C3 C3 P/L C3
NGL (C3+) FSO
C4 C4 P/L Refrig.
C4
Gas Plant
NG Plant
P/L
Condensate
FSO
Condensate/Oil
(batch loading)
Crude

Wet gas well

 CE4105 Surface Production Operations

Gathering System (GS)

§ The produced fluids from several wells are collected in centralized processing facility, i.e. Gathering Station (GS)
which seperates the fluids into three streams: oil, associated gas, and produced water

§ When the amount of the gas is significant, it is recovered and utilized for different uses (power generation,
condensate recovery feedstock, LPG production, petrochemicals production)

§ The utilization may be carried out on-site or in other location. For out-site utilization, the proceses involves gas
compression to transport the gas to distant consumer

§ The oil and emulsion from separatior (at GS) must be treated to remove water before shipping (for export or
refinery through pipelines, tanker, etc.
 CE4105 Surface Production Operations

Simple GS: Case of Balam Area

§ The simplest GS facility. It only consist of: Gas Boot,
Wash Tanks, and Crude Shipping Tanks

§ GS collects and process fluids and associated gas

from oil wells in Balam Area. The gas boot seperates
the fluids from wells into three main streams, namely
crude oil, associates gas, and produced water.

§ Processed crude oil from the gas boot is sent to

Dumai through pipeline. Produced water seperated
from gas boot is re-injected into reservoir or released
into the environment. Associated gas generated
duing separation process is sent to vent stack.
 CE4105 Surface Production Operations

GS Configuration (1)

Puncak GS
 CE4105 Surface Production Operations

GS Configuration (2)

Bangko GS
 CE4105 Surface Production Operations

GS Configuration (3)

Rantau Bais GS
 CE4105 Surface Production Operations

GS Configuration (4)

Pungut GS
 CE4105 Surface Production Operations

Gas Processing Plant (GP)

§ Gas processing plant (GP) processes non-associated gas from gas wells. Not all oil and gas fields
operation have both GS and GP

§ OIl from different oil fields are trasnported by pipelines to shipping port. Gas from oil wells (associate
gas) and gas wells are generally sent to centralized electric power and heat generation. The electric
power is distributed to different oil/gas fields while the heat is used to produce steam for steam flood
operation.

§ After separation process in the gas boot, crude oil is brougt to oil production line since the produced
water is reinjected into reservoir or release into the environment. During this process, when crude oil is
brought into the surface, it release various gases that are known as associated gas.
 CE4105 Surface Production Operations

GP Configuration (4)

Sebanga GP
 CE4105 Surface Production Operations

Gas Plant (GP)

 CE4105 Surface Production Operations

Associated Gas
§ Associated gas can be defined as dissolved gas that is released when oil fluid is in the surface (the
pressure of reservoir higher that bubble point of the gas) or release gas since the oil fluid is still in the
reservoir. This gas can be utilized for filed operation or to power plant through gas pipeline. The excess
of associated gas may be lifted, re-injected, flared, or vented.

§ Concerning the gas flared and vented, flaring can be defined as burning of associated gas and venting
or releasing of associated gas directly into the atmosphere due to there is surplus of combustible gas or
because it is uneconomic to recover the gas in the production facillities.

§ Most of GS in oil and gas production facilities process produced fluids from a number of wells, therefore
gas flare and vent at GS in higher that at other facilities.

§ Other facilities are drilling and testing facilities at oil and gas wells, gas pipeline facilities, etc.
 CE4105 Surface Production Operations

Production operations of Oil (1)

§ At the surface, well fluids are treated at the SURFACE FACILITIES through physical separation to remove
sand, water, and gas

§ Well fluids then directed to BULK SEPARATOR in which fluid being flash (sudden decrease of pressure).
Gas which has lower boiling point will directly vaporize and exit through upper section heading to
DEHYDRATOR. This gas still containing high moisture.

§ The remaining component, mostly water and oil. Oil is at the top layer being overflow and collected at
adjacent section to be transported to the oil treatment. The separated water will then transported to
water treatment section.

§ At the oil treatment section, the carried water is being seperated and sent back to water treatment
section. So the oil carried to water treatment will be sent back to oil treatment section
 CE4105 Surface Production Operations

Production operations of Oil (2)

 CE4105 Surface Production Operations

Surface Facilities
§ Separator
§ Water Treater
§ Scrubber
§ Booster
§ Filter
§ Coalescer
§ Compressor
§ Heater
§ Cooler
§ Glycol Reconcentrator
§ Flash Chamber
§ Glycol Contactor
 CE4105 Surface Production Operations

Surface Facilities
 CE4105 Surface Production Operations

Dehydrating
§ Water removal to avoid HYDRATES formation. It will cause erossion and flow obstruction inside the
pipeline (if agglomerated). Thus, dehydration is carried out as part of the surface operation.

§ Three main dehydration methods (standalone or combination):

a. Heat Management
§ Heat insulation (pipe in pipe, bundled pipe, insulated pipe, buried pipe or combination)
§ Electrical heating
b. Physical Methods
§ Pressure reduction
§ Temprature increase
§ Gas dehydration
c. Chemical Inhibition
§ Alcohol & glycol
§ Salts
 CE4105 Surface Production Operations

Type of Reservoir Fluids

§ Black Oil Reservoir (low-shrinkage crude oil)

§ Volatile Oil Reservoir (high-shrinkage

crude oil)

§ Retrogas Gas Reservoir

§ Wet Gas Reservoir

§ Dry Gas Reservoir

 CE4105 Surface Production Operations

Type of Reservoir Fluids

 CE4105 Surface Production Operations

Type of Reservoir Fluids (2)

§ BLACK OIL reservoir (low-shrinkage crude oil)

§ ...
 CE4105 Surface Production Operations

Type of Reservoir Fluids (3)

§ VOLATILE OIL Reservoir (high-shrinkage
crude oil)

§ ...
 CE4105 Surface Production Operations

Type of Reservoir Fluids (4)

§ RETROGRADE Gas Reservoir
§ ...
 CE4105 Surface Production Operations

Type of Reservoir Fluids (5)

§ WET Gas Reservoir
§ ...
 CE4105 Surface Production Operations

Type of Reservoir Fluids (6)

§ DRY Gas Reservoir
§ ...
 CE4105 Surface Production Operations

GOR
VG,SP
Vvolume gas at standard
§ GOR [=] gas to oil ratio, gSP: Volum gas
condition
pada kondosi standar
VG,ST
§ other names: dissolved gas oil ratio, gas solubility Separator
VgST : Volum gas
volume gas at
pada kondisi standar
standard condition

§ Solution GOR (Rs) = dissolved gas in oil at Stock

Tank

reservoir condition
V
VoST: Volum minyak
V
VoSP: Volum minyak O,ST
VG,SP  VG,ST
pada kondisi stock tank
scf O,SP
pada kondisi separator oil volume at stock
RS  [] oil volume at separator condition
tank condition

VO,ST STB
§ Producing GOR

§ Separator GOR Dari sumur

Reservoir
P, T, V
 CE4105 Surface Production Operations

GOR Profile

Direction Arah
of depletion
deplesi
Solution GOR, scf/STB
Solution GOR,
scf/STB

Saturated UNDERSATURATED
Undersaturated
SATURATED

PRESSURE
Tekanan Pb
 CE4105 Surface Production Operations

GOR (cont'd)
VG,SP
§ GOR [=] gas to oil ratio, Vvolume gas at standard
gSP: Volum gas
condition
pada kondosi standar

§ other names: dissolved gas oil ratio, gas solubility VG,ST

VgST : Volum gas
Separator volume gas at
pada kondisi standar
§ Solution GOR (Rs) Stock
standard condition

Tank
§ Producing GOR: ratio of volume of produced gas
V
VoST: Volum minyak
at surface (standard condition) to volume of stock tank V
VoSP: Volum minyak O,ST
pada kondisi stock tank
O,SP
pada kondisi separator oil volume at stock
oil oil volume at separator condition
tank condition

§ Separator GPR
VG,SP scf
Separator GOR  []
VO,SP bbl Dari sumur
Reservoir
P, T, V
 CE4105 Surface Production Operations

GOR (cont'd)
High-shrinkage
High shrinkage Wet Gas
crude Wet gas
crude

GOR GOR
[=]
SCF/STB
scf/STB
0 500 8.000 70.000 100.000

Low-shrinkage
Low shrinkage Retrograde Dry gas
crude
crude Retrograde Gas
condensate Dry Gas

Low shrinkage
Low-shrinkage High-shrinkage
High shrinkage
crude
crude Dryand
Dry & wet
Wetgas
Gas
crude
crude
oAPI
0API

ρ
30 50 60
γO  O Retrograde
ρW Retrograde Gas
141.5 condensate
0
API   131.5
γO
 CE4105 Surface Production Operations

Oil Formation Volume Factor, Bo

V1 - V2

Pressure reduction
Reduksi tekanan
V1 rbbl
V1 V1 bbl V2 V2 bbl
Liberated
+ Gas GAS
terbebaskan
Bo  []
Kondisi
Reservoir
reservoir
Condition
dan temperatur
and Temperature STOCK
di stockTANK
tank V2 bbl
60 F60 F
0 o

14.7 psiapsia
14,7
 CE4105 Surface Production Operations

Bo Profile
Direction of depletion
Arah deplesi
Bo
B0

Saturated
SATURATED UNDERSATURATED
Undersaturated

Tekanan
PRESSURE Pb
 CE4105 Surface Production Operations

Gas Formation Volume Factor, Bg

Vgas at reservoir
Bg 
Vgas at standard condition

At S.C:
Z = 1,
T = 600F (520 oR)
P =14.65 psia
1 bbl = 5.615 cuft

zT res bbl
B g  0.00502
P scf