Offshore

Moreover, the event revealed structural flaws in the safety management systems of offshore facilities. 

The discussion concerning Titanic disaster in Chapter 2 provides the following quotation (Brander 1995)  

The Titanic disaster suddenly ripped away the blindfolds and changed dozens of attitudes, practices, and standards almost literally overnight. 

The same comment could be applied to the Deepwater Horizon catastrophe. 

Trends to do with offshore process safety were summarized in a December 2010 Wall Street Journal article entitled Far Offshore, A Rash of Close Calls (Gold, 2010). The following quotations are taken from that article. 

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Having defined and gathered data adequate for an initial reserves estimation, the next step is to look at the various options to develop the field. The objective of the feasibility study is to document various technical options, of which at least one should be economically viable. The study will contain the subsurface development options, the process design, equipment sizes, the proposed locations (e.g. offshore platforms), and the crude evacuation and export system. The cases considered will be accompanied by a cost estimate and planning schedule. Such a document gives a complete overview of all the requirements, opportunities, risks and constraints. 

As decommissioning approaches, enhanced recovery e.g. chemical flooding processes are often considered as a means of recovering a proportion of the hydrocarbons that remain after primary production. The economic viability of such techniques is very sensitive to the oil price, and whilst some are used in onshore developments they can rarely be justified offshore at current oil prices. 

Hydrocarbons are of a lower density than formation water. Thus, if no mechanism is in place to stop their upward migration they will eventually seep to the surface. On seabed surveys in some offshore areas we can detect crater like features ( pock marks ) which also bear witness to the escape of oil and gas to the surface. It is assumed that throughout the geologic past vast quantities of hydrocarbons have been lost in this manner from sedimentary basins. 

Exploration activities are potentially damaging to the environment. The cutting down of trees in preparation for an onshore seismic survey may result in severe soil erosion in years to come. Offshore, fragile ecological systems such as reefs can be permanently damaged by spills of crude or mud chemicals. Responsible companies will therefore carry out an Environmental Impact Assessment (EIA) prior to activity planning and draw up contingency plans should an accident occur. In Section 4.0 a more detailed description of health, safety and environmental considerations will be provided. 

Semis are often used in water depths too deep for jack-ups. However, anehor handling and the length of the riser eventually impose a limit on the operating depth. Their stability makes them suitable vessels for hostile offshore environments. 

Whether onshore or offshore drilling is carried out, the basic drilling system employed in both cases will be the rotary rig (Fig. 3.7) and the following summarises the basic functions and parts of such a unit. Three basic functions are carried out during rotary drilling operations ... 

As in the construction industry, piling of the conductor is done by dropping weights onto the pipe or using a hydraulic hammer until no further penetration occurs. In an offshore environment the conductor is either piled (e.g. on a platform) or a large diameter hole is actually drilled, into which the conductor is lowered and cemented. Once the drill bit has drilled below the conductor the well is said to have been spudded. 

Not surprisingly, costs are several times higher than conventional wells. Nevertheless, overall project economics may favour ERD over other development options. For example, BP developed the offshore part of the Wytch Farm Oilfield (which is located under Poole Harbour in Dorset, UK) from an onshore location. The wells targeted the reservoir at a vertical depth of 1,500 meters with a lateral displacement of over 8,000 meters (Fig. 3.20). The alternative was to build a drilling location on an artificial island in Poole Bay. ERD probably saved a considerable amount of money and advanced first oil by several years. 

Offshore, subsea satellite development may be a viable alternative to ERD wells. 

The UK government enquiry into the Piper Alpha disaster in the North Sea in 1988 has had a significant impact on working practices and equipment and has helped to improve offshore safety around the world. One result has been the development of a Safety Management System (SMS) which is a method of integrating work practices, and is a form of quality management system. Major oil companies have each developed their own specific SMS, to suit local environments and modes of operation, but the SMS typically addresses the following areas (recommended by the Cullen Enquiry into the Piper Alpha disaster) ... 

In a normally pressured reservoir, the pressure is transmitted through a continuous column of water from the surface down to the reservoir. At the datum level at surface the pressure is one atmosphere. The datum level for an offshore location is the mean sea level (msl), and for a onshore location, the ground water level. 

Figure 5.37 depicts the basic set up of a wireline logging operation. A sonde is lowered downhole after the drill string has been removed. The sonde is connected via an insulated and reinforced electrical cable to a winch unit at the surface. At a speed of about 600m per hour the cable Is spooled upward and the sonde continuously records formation properties like natural gamma ray radiation, formation resistivity or formation density. The measured data is sent through the cable and is recorded and processed in a sophisticated logging unita the surface. Offshore, this unit will be located in a cabin, while on land it is truck mounted. In either situation data can be transmitted in real time via satellite to company headquarters if required. 

For an offshore field, recoverable volumes of less than 0.5 trillion scf (Tcf) are typically uneconomic to develop. This would equate to an oil field with recoverable reserves of approximately 80 MMstb. 

Figure 9.18 provides an overview of the application envelope and the respective advantages and disadvantages of the various artificial lift techniques. As can be seen, only a few methods are suited for high rate environments gas lift, ESP s, and hydraulic systems. Beam pumps are generally unsuited to offshore applications because of the bulk of the required surface equipment. Whereas the vast majority of the world s artificially lifted strings are beam pumped, the majority of these are stripper wells producing less than 10 bpd. 

Though the type of processing required is largely dependent upon fluid composition at the wellhead, the equipment employed is significantly influenced by location whether for example the facilities are based on land or offshore, in tropical or arctic environments. Sometimes conditions are such that a process which is difficult or expensive to perform offshore can be exported to the coast and handled much more easily on land. 

Where space and weight are considerations (such as on an offshore facility) plate separators may be used to dehydrate crude to evacuation specification. Packs of plates are used to accelerate extraction of the water phase by intercepting water droplets with... 

Skimming tanks have already been described as the simplest form of de-oiling facility such tanks can reduce oil concentrations down to less than 200 ppm but are not suitable for offshore operations. 

Another type of gravity separator used for small amounts of oily water, the oil interceptor, is widely used both offshore and onshore. These devices work by encouraging oil particles to coalesce on the surface of plates. Once bigger oil droplets are formed they tend to float to the surface of the water faster and can be skimmed off. A corrugated plate interceptor (CPI) is shown below and demonstrates the principle involved. However there are many varieties available. Plate interceptors can typically reduce oil content to 50-150 ppm. 

Hydrocylones have become common on offshore facilities and rely on centrifugal force to separate light oil particles from the heavier water phase. As the inlet stream is centrifuged oil particles move to the centre of the cyclone, coalesce and are drawn off upwards, while the heavier water is taken out at the bottom. 

The hardware items with which the processes described in Section 10.1 are achieved are called facilities, and are designed by the facilities engineer. The previous section described the equipment items used for the main processes such as separation, drying, fractionation, compression. This section will describe some of the facilities required for the systems which support production from the reservoir, such as gas injection, gas lift, and water injection, and also the transportation facilities used for both offshore and land operations. 

Beam pumping and electric submersible pumps (ESP) require a source of power. On land it may be convenient to tap into the local electricity network, or in the case of the beam pump to use a diesel powered engine. Offshore (ESP only) provision for power generation must be made to drive down hole electric pumps. 

The function of offshore production facilities are very much the same as those described for land operations. An offshore production platform is rather like a gathering station hydrocarbons have to be collected, processed and evacuated for further treatment or storage. However, the design and layout of the offshore facilities are very different from those on land for the following reasons ... 

This section describes the main types of offshore production platform and satellite development facilities, as well as associated evacuation systems. 

Floating production systems offer production facilities offshore, and will be introduced in this section. 

Artificial islands could be regarded as platforms but fall somewhere between land and offshore facilities. 

The legs of the platform can be used as settling tanks or temporary storage facilities for crude oil where oil is exported via tankers, or to allow production to continue in the event of a pipeline shut down. The Brent D platform in the North Sea weighs more than 200,000 tonnes and can store over a million barrels of oil. Topside modules are either installed offshore by lift barges, or can be positioned before the platform is floated out. 

Subsea production systems are an alternative development option for an offshore field. They are often a very cost effective means of exploiting small fields which are situated close to existing infrastructure, such as production platforms and pipelines. They may also be used in combination with floating production systems. 

In 1986 when the oil price crashed to 10 a barrel, operators began to look very hard at the requirements for offshore developments and novel slimline, reduced facilities platforms began to be considered. The reduced capital outlay and early production start up capability, coupled with the added flexibility, ensured that all companies now consider subsea systems as an important field development technique. Although the interest and investment in subsea systems increased dramatically, subsea systems still had to compete with the new generation of platforms, which were becoming lighter and cheaper. 

The template will be constructed and fitted out at a fabrication yard and then transported offshore to the drilling location. The template is lowered to the seabed using a crane barge or, if small enough, lowered beneath a semi-submersible rig. Prior to drilling the first well, piles are driven into the sea bed to hold the template in place. 

Crude oil and gas from offshore platforms are evacuated by pipeline or alternatively, in the case of oil, by tanker. Pipeline transport is the most common means of evacuating hydrocarbons, particularly where large volumes are concerned. Although a pipeline may seem a fairly basic piece of equipment, failure to design a line for the appropriate capacity, or to withstand operating conditions over the field life time, can prove very costly in terms of deferred oil production. 

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