EOR Water Injection PDF

Integrated Water Re-injection
Plant for Enhanced Oil Recovery

(Onshore Oilfields)
Copyright © Siemens AG 2010. All rights reserved.

Integrated Water Re-Injection Plant
Scope of Siemens Oil & Gas
Page 2 Claudio Ranaudo

Intelligent Water Re-injection Plant
Concept and Approach
Standardized components to provide

customized but flexible solutions
Pre – engineered
 Solution Packages
 Skid mounted equipment and ready to use
 Connecting Pipes
 Electrical Wiring and Instrumentation
 Control Center
 Modules (for single, parallel or sequential arrangement)

Integrated Water Re-injection Plant
Plant Diagram
Produced
Water Produced Water Oil & Solid Removal Skids Processed Water
from Surge Drum Skid  1 set L-S Hydrocyclone Surge Drum Skid
GOSP  1 set S-S Hydrocyclone
 1 set DGF (Veirsep-PTM)
 1 set Walnut Shell Filter
 2 set Pump Skids
Electrical Power System
Instrument Air System
unmanned Operation
Telecommunication
Injection Pump Skid
Air Compression
Piping & Layout
Control System
Manned versus
 variable speed drive system
Automation &
 high pressure
Laboratory
 including lube oil system
Station
Make Up Water
Water Conditioning
 Sea Water
 Coarse Filters Make Up Water
 Fresh Water
 Fine Filters Balance Tank
 River Water
 Deoxy Vacuum Tower WELL HEADS
 Ground Water

Pre-engineered produced water reinjection
Siemens WRI solution to be perfectly Requirement needed from Customer:

balanced between meeting client Water inlet and outlet specification
requirements, product standardization
and manufacturing time. Designed to
plug’n play.  Pre – Engineered Solution Packages water
injection 20 … 40 … 80 k BWPD
 Injection pressure range 50 – 250 bar
Standardized  Oil and Solid Removal < 10 ppm
Module
GT  Skid mounted equipment ready to use
Package
 MW range up from 0,5 MW – 4,0 MW
E&A  Ex Zone Classification 1 and 2
Container
Hydro  Oil & Gas proven standardized components
cyclone Treated
In
Water Tank
(API, ASME, EU)
Flotation
 Delivery in ca. 12 -18 months,
Pump all from one source
Walnut
Skid
Shell Filter  Plug ‘n play during commissioning
 Totally unmanned operation
 Full maintenance and operation service
Artificial view

Environmental Conditions
Arctic environment (Russia) Desert environment (Libya)
 Plant design for -40° Grad Celsius  Plant design for up to 60° Grad Celsius
 Heating tracing system for complete plant  Tropicalization of the electrical equipment
 Isolation according to client spec. and instrumentation
 Gost and RTN Certification  Housing and shelter
 Ready for train transport  Ready for ship transportation
 Bilingual documentation
Lifecycle Management - Comprehensive View
PLANT LIFE CYCLE Comprehensive

over view LIFE CYCLE
Preservation MANAGEMENT
Mechanical COVERS
INSTALLATION PHASE
Engineering & Project Completion
Management Clear punch list
Documentation
Planning
Procurement, FAT
Delivery COMMISSIONING Functional checks
ENGINEERING/ PHASE
testing & commissioning
PROJECT PHASE Putting to operation,
Training, SAT,
Completion, As built
drawings, Training
Solutions, systems,
Feed stage,
Documentations, Bid OPERATION
Management, PHASE Startup support
FEED/EPC Warranty, On call
Purchase order
PHASE service Preventative &
Planned maintenance,
Repairs, Training,
Upgrading & Retrofitting

Unique Selling Points (1)
• Plant is designed and engineered in a modular manor, e.g. skid mounted, standard
equipment, etc.
• Plant units are configurable and scalable, e.g. by means of modular concept
• Plant is designed and engineered for unmanned operation, if applicable
• Plant is supplied “turnkey”. This includes design, engineering, procurement, installation,
commissioning, and maintenance services, as well as Siemens Project Management
expertise, if applicable
• Siemens equipment and systems are included in design and engineering as thoroughly
as possible

Unique Selling Points (2)
•All actuators for control equipment shall electrically operated and compliant to e.g. ATEX
specification, SIL requirements, etc.
• Remote I/Os are installed per Unit / Skid and e.g. skid mounted. For instance, there shall
be one cabinet on skid containing power supplies and I/O modules
• DCS and SIS integrated
• All process pumps are driven by VSDS in order to increase energy efficiencies and to
minimize CAPEX and OPEX
• Plant is designed and engineered for Remote Service e.g. in order to optimize Plant
availability and spare part warehousing with respect to OPEX

Integrated Water Reinjection Plant
Our Value Proposition
Fast ROI
 Standardization
Risk Reduction
 “one-throat-to-choke”
 World-class products
 Project management and execution
Short Project Execution Time

 Pre-engineered packages
Flexibility
 Modular design
 Transportable modules
 Leasing model available
 Support testing and analysis of
reservoirs

Hypothetical example for WRI Plant
20.000 bpd, 150 bar, approx. 1,1 MW
Hydro- Flotation Walnutshell Water Surge Pump Skid

cyclone Filter Drum
Siemens/ Siemens/
Siemens Siemens Siemens
external external
LxBxH: LxBxH: DxH: DxH: LxBxH:

6mx2,5mx2,5m 10mx3mx2,1m 3,3mx7m 12mx3mx3m 10mx2,5mx3m
6 months 10 months 8 months 6 months 12 months
2 process pump
1 Skid 1 Skid 1 Skid 2 Skids skids, 1 injection
pump skid

Hypothetical example for WRI Plant
20.000 bpd, 150 bar, approx. 1,1 MW
GT Package Alternatively E&A/Comm. Eng., Pro-

Diesel Gen. Container curement, PM
75 % Siemens
Siemens External Siemens Siemens
25% External
LxBxH: LxBxH: DxH: Foot print

n.a.
6mx2,5mx2,5m 6mx2,5mx2,5m 6mx2,5mx2,5m 250 m²
12 m. of delivery
12 months 12 months 4 months 6 months after PO + 2 m.
inst./comm.
1 Skid 1 Skid 1-2 Skids n.a. 11-12 Skids

Actual Project
End User: ZADCO (ADNOC)
Overview:
- 400.000 BWPD ~ 2650 m³/hr

- 5 trains with around 100.000 BWPD Plants
- 4 trains in operation and 1 train in stand by
- Increasing of the injection water over 25 years up tp 1.2 mio. BWPD
Important for the Customer:
- Less capex
- flexibility during the lifetime
- easy to integrated a additional train in the existing plant (instrument,
electrical, control and automation system)
Contact
Claudio Ranaudo
Research and Development
E O C&S ONS TI
Stintzingstraße 24
91052 Erlangen
Phone: +49 (9131) 18-2531

Mobile: +49 (173) 368-5707
E-mail: claudio.ranaudo@siemens.com

We are happy to answer your questions!

Back Up

Water Re-injection Plant
Product Sheet – Injection Pump Skid
Water Injection Pump

 Flow up to 20.00 – 60.000 BPD
 Heads up to 2500m
 Discharge pressure
up to 250 bar
 Temperature up to 450°C
Pumps: WCC
API 610 code: BB5  Speeds up to 6000 RPM
 Variable Drive System

Product Sheet – Injection Pump Skid II
Optional WCC Shearing Design

 Quicker dismantle
 Easy maintenance
 Full cartridge design
 Applicable technology
 Suitable for Water Injection

Product Sheet – Hydrocyclone Skid
 Liquid/liquid, solid/liquid designs

 Maximum separation in a small
footprint
 Low weight, important in offshore
applications
 Hydrocyclone bundles recently
patented
 Used primarily to remove
concentrations of oil
(200 to 2,000 ppm) from
Produced Water as an initial
separation step prior to polishing
by flotation systems
Product Sheet – Flotation Skid
 Liquid and solid removal from

produced water
 Maximum separation in a small
footprint
 Low weight,
 Solid and oil removal up 20 ppm
 Low maintenance cost and long
life time
 Air or gas flotation system
 Operated under pressure or
atmospheric conditions

Product Sheet – Wallnut Shell Filter Skid
Tertiary Produced
Water Separation
 Walnut Shell Filters
 Media Filters
 Cartridge Filters
 Activated Carbon Filters
Advanced Treatment
 Biological Treatment
Solids Handling
 Gravity Thickeners
 Filter Press
 Belt Filter Press
 Sand Jetting Systems
Oil and Waste Recovery
Power Supply
Gas Turbine Generator Combined Mechanical Drive

Nominal Rating Set Cycle Output KW BHP SPEED
At ISO, Gas Fuel MW(e) MW (RPM)
4,35/4,70
SGT - 100 4,922 6,600 13,000
5,05/5,25
SGT – 200 6,75 7,680 10,300 10,950
SGT - 300 7,90
SGT - 400 12,9 17,2 13,400 18,000 9,500

Oil & Gas Production
Produced Water Treatment Process Map
Primary Secondary Tertiary

Produced Solids Produced Produced Produced Discharge
Water Separation Water Water Water or Reinjection
Separation Separation Separation for
Water Flood
To Discharge,
Chemical Advanced Reinjection
Feed Treatment or Reuse
To Disposal
VOC Auxiliary Solids

Control Equipment Handling

Water Injection/Reinjection Process Map
Well or
Surface Coarse Fine Solids To
Water Screening/ Separation/ Deaeration Injection
Strainers Filtration Sulfate
Feed
Removal
To
Polymer
Or Steam
Chemical Feed Softening Flood
Systems Systems
To
Disposal
Chlorine
Solids
Generation/
Handling
Feed Systems

Water Injection/Reinjection – Case Study
 End User:
Saudi Aramco Company
 Application:
Oil Field Water Floods.
 Location: Qurrayah Seawater
Filtration Plant, Saudi Arabia
 Scope: Sea Water Media Filters
(20 and 36) and
Electrochlorination Systems
 Flowrate: 2.5 million bbl/day and
4.0 million bbl/day
 Year: 2004 and 2006
 Order Value: $10,500,000.00
Power Generation Set – SGT 100
Lubrication
Oil Module Gas Fuel Auto Drain
DLE Module Module
(with ECU)
Liquid Fuel
Purge Module
Liquid Fuel
Supply Module
back

Process Flow Diagram
20.000 BWPD Flowrate

P&I Diagram Produced Water Surge Drum

P&I Diagram Pump Skid 1

P&I Diagram Walnut Shell Filter Skid

P&I Diagram Injection Pump Skid

Single Line Diagram

System Architecture Diagram

Plant Layout Drawing

Benefits for Customers


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Integrated Water Re-injection

Plant for Enhanced Oil Recovery

Copyright © Siemens AG 2010. All rights reserved.

Page 2 Claudio Ranaudo

Standardized components to provide

Page 3 Claudio Ranaudo

Instrument Air System

Injection Pump Skid

Page 4 Claudio Ranaudo

Siemens WRI solution to be perfectly Requirement needed from Customer:

Page 5 Claudio Ranaudo

Arctic environment (Russia) Desert environment (Libya)

PLANT LIFE CYCLE Comprehensive

Page 7 Claudio Ranaudo

• Plant is designed and engineered for unmanned operation, if applicable

• Plant is supplied “turnkey”. This includes design, engineering, procurement, installation,

commissioning, and maintenance services, as well as Siemens Project Management

Page 8 Claudio Ranaudo

specification, SIL requirements, etc.

be one cabinet on skid containing power supplies and I/O modules

• DCS and SIS integrated

minimize CAPEX and OPEX

availability and spare part warehousing with respect to OPEX

Page 9 Claudio Ranaudo

Short Project Execution Time

Page 10 Claudio Ranaudo

Hydro- Flotation Walnutshell Water Surge Pump Skid

LxBxH: LxBxH: DxH: DxH: LxBxH:

6 months 10 months 8 months 6 months 12 months

Page 11 Claudio Ranaudo

GT Package Alternatively E&A/Comm. Eng., Pro-

LxBxH: LxBxH: DxH: Foot print

1 Skid 1 Skid 1-2 Skids n.a. 11-12 Skids

Page 12 Claudio Ranaudo

End User: ZADCO (ADNOC)

- 400.000 BWPD ~ 2650 m³/hr

Important for the Customer:

Phone: +49 (9131) 18-2531

Page 14 Claudio Ranaudo

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Water Injection Pump

Page 17 Claudio Ranaudo

Optional WCC Shearing Design

Page 18 Claudio Ranaudo

 Liquid/liquid, solid/liquid designs

 Liquid and solid removal from

Page 20 Claudio Ranaudo

Gas Turbine Generator Combined Mechanical Drive

SGT – 200 6,75 7,680 10,300 10,950

SGT - 300 7,90

SGT - 400 12,9 17,2 13,400 18,000 9,500

Page 22 Claudio Ranaudo

Primary Secondary Tertiary

VOC Auxiliary Solids

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