OVERVIEW: OIL & GAS INDUSTRIES,
UPSTREAM PRODUCTION FACILITIES
(FSF/FPF/CPF)
OUTLINE
 Introduction
 Field Surface Facilities (FSF)
 Field Production Facilities (FPF)
 Central Processing Facilities (CPF)
 Control System
 Power Generation and Distribution
Crude Oil Characteristics
What is Oil?
Crude oil is a mixture of carbon (84%), hydrogen
(14%), sulfur (1-3%), and nitrogen, oxygen, metals,
and salts (less than 1%). Crude oil is processed to
remove unwanted materials and produce products
such as motor gasoline, diesel, jet and home heating
fuels, waxes, asphalt, feedstock and other
components.
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Some of the non hydrocarbon compounds present
in crude oils can pose major problems in the
processing and handling of crude oils.
These includes but is not limited to:
1. Sulfur compounds
2. Nitrogen compounds
3. Oxygen compounds and
4. Metallic compounds
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Some hydrocarbon compounds found in crude
oils can also pose major processing and handling
problems such as.
1. Aromatics
2. Asphaltenes
3. Naphthenes
4. Wax
5. Petroleum acids and
6. Porphyrins containing Vanadium, nickel etc.
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Crude Oil Production: Sources of water in
Crude Oil
Geology tells us that crude oil is formed over millions
of years within what is known as “source rocks”. It is
generally theorized that gas, oil and salt water occupy
pore spaces between the grains of sandstones or pore
spaces between grains of limestone's and dolomites
which form the source rock.
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The rocks containing the gas, oil and salt water are
sealed by a layer of impermeable rock, trapping the
petroleum accumulating within the confines of the
source rock and forming the reservoir. Under the
effects of pressure and gravity from the source rock
the gas and oil migrate until they are trapped in
another capped seal rock. Because of the differences
in densities, gas, oil and water segregate within the
trap rock.
Gas if present will occupy the upper part of the trap
and water occupies the bottom part of the trap while
the oil is trapped in between the gas and water.
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Some salt water stays with the gas and or oil
within the pore spaces and as a film covering
the surfaces of the rock grains and this water
is known as connate water, and it may occupy
from 10% up to 50% of the pore volume.
Much of the crude oil is derived from
sandstone formations.
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These formations consist of combinations of silicon
and oxygen that tend to form as partially charged,
anionic (negatively charged) crystallites. These
crystallites have a high affinity for water and are
often found in close association with water. This
close association is due to the phenomenon of
hydrogen bonding, where the partially positive
hydrogen of the water interacts with the partially
negative oxygen of the silicate (SinO2n).
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What is Natural Gas?
Natural gas occurring underground is composed largely of
methane (70-90%) and other hydrocarbons such as ethane,
propane and butane. However, at natural gas processing
facilities, most of these other substances are separated out so
that the natural gas that we use is composed almost entirely
of methane. Natural gas can be produced from either natural
gas wells, which primarily produce raw natural gas, or from oil
wells where natural gas is recovered along with oil. Natural
gas can also be produced from coal-bed methane (CBM) wells.
Coal-bed methane, a type of natural gas, is located within coal
seams. To be extracted, the seam has to be depressurized by
pumping huge volumes of groundwater to the surface.
According to one Montana Department of Environmental
Quality study, a single well can produce more than 23,000
gallons of water a day. The water has been difficult to manage
because of the large quantity and the potential for poor
quality - it contains sodium and other salts that can kill plants
and damage soil.
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PETROLEUM PRODUCTION PROCESS
PRODUCTION AND PROCESS FACILITIES
FSF
FPF
FSF
Field 2
FPF
FSF
FSF
Field 3
FPF
= OGM
Wellhead
Marine
Terminal
CPF
Field 1
FPF
WELLHEAD
 Maintains surface control using choke
 Prevent well fluids from leaking or blowing at the
surface
 Design to withstand pressures of up to 140 MPa(1400
 Consist of three components,
I.Casing head
II.Tubing head
III.Christmas Tree
WELLHEAD
OIL GATHERING MANIFOLD (OGM)


It serves two purposes:
I.
To collect production from several individual wells and direct it
via a production manifold to a gathering line, a gathering station,
or a field pump station
II.
To direct production via a test header from a selected well to a
well test skid located at each manifold
Located adjacent to a producing well
ELECTRIC SUBMERSIBLE PUMPS
 Electrically driven and submersible
 Consist of three units
I. Electric Motor
II. Protector
III. Multistage Centrifugal Pump
 Operation is controlled by a control box
ELECTRIC
SUBMERSIBLE
PUMPS
 Designed to pump at very high flow rates (100 to
10,000 BPD)
 Less efficient than other types
 Expensive
 Sensitive to solids and free gas
 If conditions are favorable, ESPs can run several years
PROGRESSIVE CAVITY PUMPS
PCP Pumps
SEPARATORS
 Mechanical devices where gas is flashed from the liquids
and “free water” is separated from the oil
 Can be either horizontal, vertical and spherical in
configuration
 Two types, Production separator and Test separator
 Can be either two phase and three phase separator
 Most oil contracts specify a maximum percent of basic
sediment and water (BS&W) that can be in the crude
 Typically vary from 0.5% to 3% depending on location
 Water from the separators must be treated to remove
small quantities of produced oil
SEPARATORS
STAGING OF SEPARATORS
TWO PHASE SEPERATORS
THREE PHASE SEPERATORS
Gas
Demister
Gas
Feed
Oil
Water
Weir
Water
Oil
COMPRESSOR

Consist of
I. Scrubbers- remove liquid droplets
II. Heat Exchangers
HEAT EXCHANGERS
DEHYDRATOR/DESALTER
 Dehydration
 Desalting
 Consists of three primary steps
I. Injection of wash water
II. Contact between the wash water and the
soluble salts, and
III. Separation of the aqueous phase – most of the
installed hardware is involved in the phase
separation step
DEHYDRATOR
DEHYDRATOR
DESALITNG
Oil Outlet
Second Stage
Desalter
First Stage
Desalter
Oil
Feed
Mixing Valve
Mixing Valve
Recycle Water
Recycle Pump
Dilution
Water
Water
to
Disposal
FLARE SUBSYSTEM
 Include Flare, atmospheric ventilation and blow down
 Provide safe discharge and disposal of gases and liquids
resulting from:
I. Spill-off flaring from the product stabilization system
(Oil, Condensate etc.)
I. Production testing
II. Relief of excess pressure caused by process upset
conditions and thermal expansion
I. Depressurization either in response to an emergency
situation or as part of a normal procedure
I. Planned depressurization of subsea production
flowlines and export pipelines
FLARE SUBSYSTEM
METERING SKID
BOOSTER PUMPS
DESANDERS
SKIM TANKS
WATER INJECTION UNITS
GAS KNOCKOUT DRUM
INDUCED GAS FLOTATION UNITS
CONTROL SYSTEM
 Provide automatic day-to –day control of oil field
production system
 Supervisory Control and Data Acquisition (SCADA)which monitors and controls and DCS
 Consists of the following subsystems;
I. A human–machine interface (HMI)
II. A computer system
III. Remote terminal units (RTUs)
IV. Programmable logic control (PLCs)
V. Communication infrastructure
VI. Various process and analytical instrumentation
CONTROL SYSTEM (PLCs)
CONTROL SYSTEM
TYPICAL BASIC SCADA
TYPICAL BASIC SCADA
POWER GENERATION AND DISTRIBUTION
Provided from main power or from local diesel
generator sets
Large facilities have great power demands, from 30
MW and upwards to several hundred MW
Voltage levels for High, Medium and Low voltage
distribution boards are 13- 130kV, 2-8 kV and 300600 V respectively
Power is generated and exchanged with mains or
other facilities on the HV distribution board
Relays for protection functions
POWER GENERATION AND DISTRIBUTION
POWER GENERATION AND DISTRIBUTION
Power management system is used for control of
electrical switchgear and equipment
Includes HV, MV and LV low voltage switchgear
Motor Control Centers (MCC) and emergency
generator sets
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