Oil and gas production handbook

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CONTENTS
 1 Introduction.......................................................................................................4
 2 Process overview..............................................................................................6 2.1 Facilities..................................................................................................7
2.1.1 Onshore..........................................................................................8
 2.1.2 Offshore.........................................................................................9
2.2 Main Process Sections...........................................................................12
2.2.1 Wellheads....................................................................................12 2.2.2
Manifolds/gathering.....................................................................12
2.2.3 Separation....................................................................................13
2.2.4 Gas compression..........................................................................14
 2.2.5 Metering, storage and export.......................................................15
 2.3 Utility systems.......................................................................................16
3 Reservoir and Wellheads................................................................................17
3.1 Crude oil and Natural gas......................................................................17
3.1.1 Crude Oil.....................................................................................17
3.1.2 Natural Gas..................................................................................18
3.1.3 Condensates.................................................................................19
 3.2 The Reservoir........................................................................................19
3.3 Exploration and Drilling........................................................................21
 3.4 The Well................................................................................................24
3.4.1 Well Casing.................................................................................25
 3.4.2 Completion..................................................................................26
 3.5 Wellhead...............................................................................................27
 3.5.1 Subsea wells ................................................................................29
3.5.2 Injection.......................................................................................30
3.6 Artificial Lift.........................................................................................30
3.6.1 Rod Pumps...................................................................................31
3.6.2 Downhole Pumps.........................................................................31
 3.6.3 Gas Lift........................................................................................32
 3.6.4 Plunger Lift..................................................................................33
3.7 Well workover, intervention and stimulation........................................33
3.8 Unconventional sources of oil and gas..................................................35
 3.8.1 Extra Heavy Crude ......................................................................35
3.8.2 Tar sands......................................................................................36
 3.8.3 Oil Shale......................................................................................36
 3.8.4 Coal, Coal Gasification and Liquefaction....................................37
3.8.5 Methane Hydrates........................................................................37
 3.8.6 Biofuels........................................................................................38
3.8.7 Hydrogen.....................................................................................38
4 The Oil and Gas Process.................................................................................40
4.1 Manifolds and Gathering.......................................................................42
4.1.1 Pipelines, and Risers....................................................................42
 4.1.2 Production, test and injection manifolds......................................42
4.2 Separation..............................................................................................43
 4.2.1 Test Separators and Well test.......................................................43
4.2.2 Production separators...................................................................43
4.2.3 Second stage separator.................................................................45
4.2.4 Third stage separator....................................................................45
 4.2.5 Coalescer .....................................................................................46
 4.2.6 Electrostatic Desalter...................................................................46
4.2.7 Water treatment...........................................................................46
 4.3 Gas treatment and Compression............................................................48
 4.3.1 Heat exchangers...........................................................................48
 4.3.2 Scrubbers and reboilers................................................................49
 4.3.3 Compressor anti surge and performance......................................50
 4.3.4 Gas Treatment..............................................................................54
4.4 Oil and Gas Storage, Metering and Export...........................................54
 4.4.1 Fiscal Metering............................................................................54
 4.4.2 Storage.........................................................................................57
4.4.3 Marine Loading...........................................................................58
4.4.4 Pipeline terminal..........................................................................58
 5 Utility systems................................................................................................59
 5.1 Control and Safety Systems..................................................................59
 5.1.1 Process Control............................................................................59
5.1.2 Emergency Shutdown and Process Shutdown.............................62
 5.1.3 Control and Safety configuration.................................................63
 5.1.4 Fire and Gas Systems...................................................................65
5.1.5 Telemetry / SCADA....................................................................66
5.1.6 Condition Monitoring and Maintenance Support........................67
 5.1.7 Production Information Management Systems (PIMS)...............68
5.1.8 Training Simulators.....................................................................69
 5.2 Power generation and distribution.........................................................69
 5.3 Flare and Atmospheric Ventilation.......................................................71
5.4 Instrument air........................................................................................72
 5.5 HVAC...................................................................................................72
 5.6 Water Systems.......................................................................................73
5.6.1 Potable Water...............................................................................73
5.6.2 Seawater.......................................................................................73
5.6.3 Ballast Water...............................................................................73
5.7 Chemicals and Additives.......................................................................74
 5.8 Telecom.................................................................................................77
6 Units................................................................................................................78
 7 Acronyms........................................................................................................80
 8 References.......................................................................................................82