You are on page 1of 15

CHAPTER 6

FACILITIES ENGINEERING

This chapter will give the ideas about the……

6.1 Development Options Summary

The Arena field is located ----km (northwest/ southwest/ etc) of the ----,
offshore Sabah, East Malaysia in water depth of 50m. Through screening process,
XXX field is selected for production handling due to facilities availability and is the
nearest field to the Arena field which is approximately ----km. The Arena field consist
of 14 wells total which is 9 producers and 5 injectors to be completed using ----------
in open hole section with wire wrapped screen (WWS) for sand control purpose. (gas
lifting aspects?). Among the major aspect considered for the screening process in
selecting the developing the right platform is safety in order to ensure all the activities
and operations can be carried out prudently and effectively from time. Hence, the
maintenance costs also can be minimized in the future. Among the development
options considered are as follows,

a) Leasing Floating, Production, Storage and Offloading (FPSO)


In developing a new field located in the established offshore regions, FPSO is
one of the significant options need to be thoroughly examined with the
consideration of no pipeline facilities and if the pipeline construction and the
supporting facilities are cost an arm and a leg. The nearest locations in farming
out the FPSO vessels is Junta field operated by OG Company. The distance of
Arena field to the Junta filed is approximately……….km. benefit and
disadvantages?

b) Constructing a Central Processing Platforms (CPP), Unmanned platform


for Arena field.

Constructing a CPP is a vital structure for an oil field in processing the fluid
produced during the production and proceeding with the fluid separation
process (i.e. oil, gas, water). However, some of consideration must be
thoroughly analyse in constructing the CPP such that either it will be
economically feasible or vice versa depending on the size of the field. The main
following components considered in building CPP are separation unit, gas
compression and dehydration, produced water conditioning and water
processing and injection system. The unmanned platform concept of Self
Installing Platform (SIP) can be considered through this option.

c) Tie-ins to existing platform.

For the cost basis, tie-ins to the existing facilities can reduce the processing
cost as well as the cost for building a CPP. This option will consider CPP of
the neighbouring field (Armada field). The distance to the nearest CPP is the
major concern in selecting the location for tie-ins purpose. There are several
locations to be reviewed: the processed oil will be transported to Omega via --
--km pipeline.

The facilities of Arena field shall be constructed and operated in a manner


that complies with applicable legal, regulatory and social requirements in all material
respects.

6.2 Project Execution/ Implementation phase

The Arena filed is expected to produce ------MM of oil and ----MM of gas per
annum along with approximately ----barrels of water/condensate per day at peak. Gas
produced from the Arena field, approximately ----km offshore of Sabah, will undergo
preliminary processing offshore to remove water and extract condensate. The scope of
work of Arena field consists in the Engineering, Procurement, Construction and
Installation of ---km, ---XX” subsea pipeline, in water depth of up to 50 m, connecting
to the offshore CPP facility of Armada field.
----in case for gas production using trunklines
The trunklines and production flowlines projects approximately ---km long, in
addition to subsea pipelines about ----km long. Another components of umbilicals,
flowlines, power and fibre optics cables were installed as well.
----in case for transporting production stream
Two XX” sealines about XX km long to transport the production stream from
the wellheads to ---our CPP/ Armada’s CPP for treatment, processing, storage and
preparation for exporting purpose.

6.3 Facilities Design Basis

The designing of facilities for Arena field is according to the guidelines design,
including PETRONAS Technical Standards for Onshore Productions Installations –
Requirements and Guidelines for Emergency Response (Amendments/ Supplements
to ISO 15544).

One of the main aspects need to consider in developing a field is designing the
facilities in such a way all the servicing vessel and barges can be accommodate for
long period of time hence the maintenance costs related facilities could be reduced.
The facilities for Arena field are designed with the basis of ability to withstand design
lifetimes of 30 years with the consideration of weather condition around Sabah
offshore especially the monsoon weather environment occurs usually in September to
December and is expected alternating annually. As oil and gas fields in Sabah are
operated by Carigali, all the data and information will be handled by SBO which base
of its operation located at Menara PETRONAS, Kota Kinabalu. Summary of the
geological data of I Arena field are as follow:

Platform name : Arena platform-1 (ARN-1)

Location : Somewhere around Sabah


Wells : 9 producers and 5 injectors (14 wells in total). The producers
consist of 7 J Profile and 2 S Profile wells.

Table 6.1 Summary data of Arena field.

Fluid Properties Data


Properties/ Characteristics
Initial Reservoir Pressure, psi 1,812
Reservoir Temperature, F 149
Bubble Point Pressure, psi 1,740
Pressure Gradient, psi/ft
API Gravity, API
Specific Gravity? (water/ gas???)
Average GOR, scf/ stb
H2S and Wax Content, % w/w 0
N2 Content, % w/w 0.31
CO2 Content, % w/w 0.84
Development Data
Stock tank oil in place (STOIP)
Recovery Factor, % 18.225
Recoverable Reserves MMSTB
Production Plateau, bpd 5,500
Capital Expenditures, RM
Distance from the shore, m 40,000
Overall Length, m
Water depth, m 50
Storage Capacity (if any)
Field Lifespan, years 20
Artificial Lift
Nearby onshore location
Omega Field
Armada Field
The start-up of the production is expected at the end of 20XX.

6.3.1 Offshore Platforms

One of the vital structure purposely used for the exploration, well intervention
as well as the production fluids extraction is the offshore platforms, mainly made by
steel, concrete or combination of both, and normally installed in the area that are quite
a distance from the shore. Water depth is the main aspects need to be taken care of in
selecting the best platform design. Malaysia approximately has 300 shallow water
fixed platforms variously operated in Peninsula Malaysia Operation (PMO), Sarawak
Operation (SKO) and Sabah Operation (Twomey, 2010). As purported by Amila et al.,
2012, most of the shallow water platforms identified are suitable for Peninsula
Malaysia waters region in which the ranges of water depth recorded are from 50 to 70
m. According to 2008 PETRONAS Guidelines for Decommissioning of Upstream
Installation, the water depths less than 200 m are considered shallow waters. While
water depth beyond 300 m is generally classified as deep water (PPGUA 3.0 – V8
(Drilling and Well Operations)).

Designing platforms for Arena field should be safely function for the whole
structure especially subjecting to water depth and harsh marine environment or fatigue
loads resulting from waves forces hence contributing motion to the platform. The
options for selecting the platform that suits the development of Arena field will include
unmanned wellhead platform (i.e. satellites wellhead platform) designed for operating
without presence of personnel and the necessary facilities can be kept to a minimum
for unattended operations and activities. Besides, the current type of this platform
consists of remote well testing equipment and equipped with air compressors and test
separator (Wan, 1988). The benefit in providing a cost-effective means offer the better
choice especially for the small-scale development field such as Arena field. Normally,
unmanned planned platform consists of cellar deck, main deck, mezzanine deck and
helideck. (Laik, 2018) ---Say something abt unmanned satellite platform. Table 6.2
below showing that by using the unmanned satellites could reduce about US$ 140
million in capital cost and approximately US$ 7 million for operating cost.

Table 6.2 Cost Comparison between Manned and Unmanned Satellites for EMPI’s
Guntong, Tabu and Palas Oil Field. (Wan, 1988)
Aspect Manned Satellites Unmanned Satellites
Capital Investments, US$ 440 300
Annual Operating Cost, US$ 27 20
No. of Crew/ Personnel 224 124

Another consideration would be SIP.

6.3.2 Top Structures

As the platform size depends on facilities to be installed on the top side (i.e.
helipad, living quarters, oil rig, helipad), the selection of top side structures also must
be carefully examined. The structure will be constructed from high-grade marine steel,
with corrosion provided by anti-corrosion/ anti-fouling paint.

6.3.3 Substructures

For the installation of ARN-1, the topsides are supported on an eight-legged


jacket structure, braced, steel-structures with pin piles will be used for the docking
guides. The base design of the jackets incorporates three piles sleeves at each corner
for accommodating the 12 piles required to anchor it to the seafloor at the offshore
location.
 As for tie-ins purpose, riser platform will be installed for exporting the fluids
production. The material used for designing risers will be corrosion resistant
alloy.
 This platform is designed for a total 40 risers and J-tubes used for umbilicals
and control cables, and 10 caissons.
 Ancillaries will include two platform cranes and supports for bridges to the
riser and process platforms. The platform will be based on 4x12 well slot
configuration, giving 48 well slots in total.
 Pile leg?

6.3.4 Surface and Operation Facilities and Equipment

The surface processing facility should provide power, communication and


chemical injection (if any) services back to the subsea production system. The
preferred facilities and equipment for surface and operation of Arena field are based
on these four (4) criteria which are --------THINK THINK THINK

6.3.4.1 Wellhead

Wellhead valve equipment will be equipped with a master valve and a surface
safety valve (SSV) in the Christmas tree.

6.3.4.2 Production Flowlines, Flow Control and Manifold

Developing the Arena field involving multiple wells in the subsea in which the
produced fluids will be delivered to the subsea production manifolds from flowline
jumpers of individual wells. The number of flowlines for the next production activity
could be reduced by routing and monitoring the fluids from multiple wells. As the
fluids from each well reaching the manifold and are commingled, then they are passed
to a flowline to be delivered to the production platform. The installation will include
pipeline end manifold (PLEM) designed to connect a flowline with another subsea
structure or joining main pipelines with a branch pipelines. For Arena field, using
PLEM is to incorporate the tie-in points with other components of the nearest filed.

6.3.4.3 Gas Metering and Measurement

Three types of gas metering commonly used which are operational meter,
allocation meter and custody meter. Besides its lower in cost, the operational meter is
usually used for the offshore operation because of the flow pressure and temperature
are already different at the moment it reaches the terminal compared to offshore,
therefore offshore reading flow are most likely dissimilar to the terminal reading flow.

6.3.4.4 Water Injection Systems

6.3.4.5 3-Phase Separator (if any)

CPP will be equipped with three (3) phase horizontal/ vertical separator. The
separation process will be assisted by chemicals to enhance the demulsification of
water and oil. The gas is routed to a gas compression and dehydration unit, water flows
into a water conditioning unit while the separated oil will be allowed to flow into the
oil manifold. ( http://www.drillingformulas.com/what-is-central-processing-
platforms-cpp/ )

6.3.4.6 Crude Oil Processing and Gas Handling


6.3.4.7 Gas Lifting Equipment

Due to bigger volume of gas resource available for production, gas lift
configuration slickline wireline type with gas lift valve change (GLVC) is used for
production enhancement purpose. Besides, with the gassy oil and sandy properties of
Arena field, the application of gas lifting method is highly recommended. The usage
of gas lift can be considered based on productivity index (PI) and bottom holes
pressure (BHP) of the wells, (i.e. High PI with high BHP, high PI with low BHP, low
PI with high BHP or low PI with low BHP) -----WILL BE DISCUSSED MORE IF
THIS PART ARE REQUIRED

BOOSTING PUMP???

6.3.4.8 Electrical, Lighting, Instrumentation and Control System

Electrical power and lighting shall be covered in all working areas inside and
outside of the platform and for the proper illumination of vital areas such as drilling
rig, control stations and well control equipment, stairway, passage ways and
emergency generator area, the emergency lighting shall be provided. The electrical
system installed will be grounded and are able to operate safely and effectively under
critical and hazardous situations. The control stations will be equipped with an
emergency shutdown switch purposely to shutting down the electrical equipment and
power plants in case of the emergency.

6.3.4.9 Drainage System and Waste Disposal

sart
6.3.4.10 Air System and Ventilation

All the confined areas including working area should be adequately pressurized
and ventilated. Blowers and fans will be equipped together with remote shut-off
switch. Gas turbine containing exhaust pipes should be provide with proper flames and
be insulated aiming to avoid any ignition and safely vented to the atmosphere.

6.3.5 Safety Facilities

ggh

6.3.5.1 Safety Shutdown System

Minimum of one-unit emergency shutdown control station will be equipped at


the drillers during well operations and activities especially unit without presence of
drillers will be provided with readily accessible ESD stations.

6.3.5.2 Flaring/ Venting System and Pollution Prevention?

6.3.5.3 Gas Detection with Alarm System

The platform will be equipped with and gas detection system that can
continuously monitor especially at the confined areas where there are high possibilities
accumulation of combustible gas or vapors.
6.3.5.4 Fire Fighting Equipment and Alarm

Firefighting equipment and alarm shall be provided and maintained at every


drill site to combat all classes of fires. Each drilling unit should have readily accessible
at least two (2) proximity firefighting suits and four (4) self-contained portable
breathing devices. Each drilling unit also will be provided with fire alarm system-
includes-detectors located in the engine rooms, boiler rooms, pump and mud tank
rooms and in the accommodation in which it can automatically sounding an alarm and
indicating on a panel the fire location.

6.4 Development and Screening Process

As emphasized under subchapter development options summary, the selection


for Arena field will be based on these three (3) cases listed below:

6.4.1 Case 1: Leasing FPSO, CPP??? (DON’T KNOW TO EXPLAIN)


6.4.2 Case 2: Unmanned Satellite Platform, one CPP

Fluid produced at ARN-1 will be transported to ARN-CPP by the


approximately 30 km pipeline. ------DESCRIBE THE PROCESS
----pls provide the diagram (questor)-----

6.4.2.1 Topside

The ARN-1 topside structure will consist of two level facility with,
 The upper/ main/ weather deck consisting of drilling/ derrick equipment set
(DES) that operates 24 well slots. DES also will be equipped with drill floor
equipment, drilling sloid control system as well as equipment for well control.
 A fixed drilling support module (DSM) that include fuel tank, storage tank,
mud mixing and tank, control system, etc. to supply power, circulations and
other necessary support for drilling, separation, utilities as well as
accommodation for platform crew.
 The structure will be constructed from high-grade marine steel, with corrosion
provided by anti-corrosion/ anti-fouling paint.
 Module support frame (MSF) (if any)-----------------------
 No living quarters will be provided (i.e. unmanned).
 One unit of helideck and XX unit of cranes?
 Bridge link between the wellhead platform and CPP will be 70m long, 4.5m
wide and 7m tall and will provide personnel access and service between the
two platforms. The bridge will be constructed by using steel lattice structure
with service supports and cable rack to support pipework, cabling and
connections required for the transfer oil fluids production, electricity between
the two-topside platform.
 The lower/ cellar deck facilities include manifolds of production including
tied-back), sand separation package and general utilities.
 Topside dry weight will be ---------metrics tons and topside dimensions (100m
x 25m / 125m x 30m / 40m x 83m)

6.4.2.2 Three (3)-Phase Separator


6.4.2.3 Pump

Pump sizing must be properly design that suits the liquid flow rate to be piped.
Another aspect need to be considered is the total differential head of the pump to
deliver the fluid to the destination.

Table 6.X Parameters required for pump sizing.


Suction static head, m 69
Discharged static head, m (assumption) 70
Total differential head, m 2
Frictional head loss, m (assumption) 5
Flow rate, m3/s 0.05
Liquid density, kg/m3 828
Acc. due to gravity, m/s2 9.81
Efficiency of the pump, % (assumption) 92

6.4.2.4 Compressor

For discharging the gas produced from ARN-1 to Omega terminal, the
compression ratio needed,
DIscharge Pressure, psia
Compression Ratio =
Suction Pressure, psia

Based on the calculated compression ratio of XX, the suitable compressor for
transporting gas produced to Omega terminal would be ---------.

6.4.3 Case 2: Self Installing Platform (SIP), one CPP

Topside
The ARN-1 topside structure will consist of two level facility with,
 The upper/ main/ weather deck consisting of drilling/ derrick equipment set
(DES) that operates 48 well slots. DES also will be equipped with drill floor
equipment, drilling sloid control system as well as equipment for well control.
 A fixed drilling support module (DSM) that include fuel tank, storage tank,
mud mixing and tank, control system, etc. to supply power, circulations and
other necessary support for drilling, separation, utilities as well as
accommodation for platform crew.
 The structure will be constructed from high-grade marine steel, with corrosion
provided by anti-corrosion/ anti-fouling paint.
 Module support frame (MSF) (if any)-----------------------
 Other than serving as the control room, the living quarters capable to support
200 persons onboard (POB) for normal operation and activity and up to 300
POB for commissioning as well as shutdown operation. Nine lifeboats will be
provided at the main mustering stations located on the living quarters.
 One unit of helideck and XX unit of cranes?

6.4.4 Case 3: Tie-ins to Armada CPP

For minimizing the development cost, it is recommended that Arena filed


should be tie in to the nearest existing facilities, which is Armada field by the subsea
pipeline system. The fluid production will be processed using CPP of Armada (AMD-
CPP). Despite the higher cost in leasing the FPSO vessels for 25 years duration time
and highly cost processing on ARN-1, the options to tie-in to the nearest existing
platform is selected based on the minimizing cost basis for current and the future of
Arena budget planning. The products will be collected at the ARN-1 via 8” flowlines
and transported to Armada CPP via AMD-1 x 40” trunklines (transporting gases)
The route and configuration of the tie in line between the Arena field and Armada
should be clearly defined that it can ensure the project is smoothly implemented. The
project deliverables to be executed encompasses the aspects of engineering,
procurement, fabrication and installation of:

a) Wellhead gas platforms


b) Launcher and receiver facilities
c) Intrafield flowlines and MEG line
d) Power cables and umbilicals – to supply electric power, hydraulic fluid and
chemicals. (Crucial aspects: quantity crossings required especially at the tie-in
platform)

6.4.1 Optimum Sizing of Pipelines (PIPESim)


6.5 New Technologies
6.6 Schedule
6.7 Facilities CAPEX
The proposed options for the facilities development of Arena Field are as
follows;
i. Leasing FPSO, CPP??? (DON’T KNOW TO EXPLAIN)
ii. Unmanned Satellite Platform, one CPP
iii. Tie-ins to Armada CPP

You might also like