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Petroleum Engineering Design Project: Gullfaks Production Facilities Phase 2

Report

Technical Report · December 2014

DOI: 10.13140/2.1.4708.5120

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 BENG(HONS) - PETROLEUM ENGINERRING
MODULE EAC-6-929

Petroleum Engineering Design Project:

Gullfaks Production Facilities
Phase 2 Report
Prepared by: Arcanjo Wacunzo – ID 3021399
Prepared for: Andrew Fergusson-Rees

London South Bank University

2014/2015
 [PHASE 2] December 12, 2014

List of content
Title

1. Abstract ----------------------------------------------------------------------------page 2

2. Introduction--------------------------------------------------------------------------------page 3

3. Surface Production in the Gullfaks------------------------------------------------------page 4

3.1 Block Diagram of surface production---------------------------------------------page 5

3.2 Subsea Separator----------------------------------------------------------------------page 6

3.3 Oil, gas and water treatment--------------------------------------------------------page 7

4. HSYSY Simulation----------------------------------------------------------------------page 8

4.1 Mass balance and Energy Balance calculated on HYSYS and Excel.-------page 10

4.2 Sensitivity Analysis-----------------------------------------------------------------page 12

Conclusion and Discussion----------------------------------------------------------------------page 13

References-----------------------------------------------------------------------------------------page 14

Attachments: HYSYS block diagram -------------------------------------------------------- page 15

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1. Abstract
This work was undertaken under request of Dr. Andrew Fergusson-Rees following the
second phase of the final project which is about the Gullfaks field. The work will show
information related to the subsurface equipment of the field, methods which are being
implemented within the field and production facilities. This will also provide production
information and some of the properties of the oil produced on this field.

On this paper will be discussed the water treatment, the previous separator used and the
new that was emplemented and why it had to be implemented. Also, the compressor and
all the process used on this field such as the gas and how fluid is produced within the
three different platforms Gullfaks A, B and C.
Furthermore, the HYSYS simulation was used to design the production facility and
achieve some specifications such as the inlet feed had to be stored at 4bar and above
60°C, gas reinjected at 50 °C and 120 bars. The gas condensate to be collected for further
treatment and the same happens with the water produced.
Finally, after having designed the oil production facility and confirmed the export oil and
export gas conditions and properties a case study was opened and following sensitivity
analysis to analyse the effects of the separator temperature variation on the process.

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2. Introduction

The Gullfaks is a Norwegian oil and gas field which is located in the North Sea area
discovered in 1978. The field lies in block 34/10 covering an area of 75 km2 and it has been
developed with 3 production platforms. The first platform is A which began production on
the 22nd of December 1986, subsequently platform B in 1988 and the last 1989 platform C.

Figure 1: Image showing The Gullfaks field and the three platforms. (Ref. Image from Statoil website)

The field has a licence until 2016 which will be extended to 2030; companies operating are
STATOIL with 51%, PETORO with 30% and NORGE 19% shares.
Blocks and production licenses:

 Block 34/10 - licence 050, given 1978

 Block 34/10 – license 050 B, given 1995

Reservoir Characteristics:
 API: 36
 Area: 50km2
 Oil Density: 826 kg/m3
 Viscosity: 3.4 cp
 Oil-Water Contact: 1947 m TVD
 Initial Pressure: 210 bar
 Bubble point pressure : 220 bar
 Initial temperature: 72 ° C
Production rates estimated in 2013:
 Oil: 39 000 barrels/day
 1.5 BN Sm³ gas
 0.2 mill tonnes NGL
Reserves:
Original Oil in Place:
 365.5 million Sm³ oil
 23.1 billion Sm³ gas
 2.8 million tonnes NGL
Remaining as of 31.12.2012
 11.6 million Sm³ oil

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 [PHASE 2] December 12, 2014

3. Surface Production in the Gullfaks

3.1 Block Diagram of the surface production

Figure 2: Block diagram used in the Gullfaks field for oil processing. (Ref. Aker Solutions
Website)

The field has three integrated processing plant with just first stage for separation. Platform B
has a basic processing plant with only first stage separation. Whereas A and C receive and
process oil and gas from Gullfaks Sør and satellites.

The fluid oil water and gas are transported through manifolds to the subsea separator via 2
pipelines, some of the water is used to inject into the reservoir and other is carried out with
the oil and gas to the topside of the Gullfaks C separator.

Multiphase pump are being used. The pump is used because the platform C has 11km
pipelines and the pump enables to operate the subsea separator in a low pressure besides of
the friction loss caused by the long pipelines.

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3.2 Subsea Separator

The subsea separator is used in order to meet the required export sales specification. The 2-
phase separator is used to separate liquid and gas and this happens inside the separator due to
gravity. The water (H2O) which is heavier sinks and stays in the bottom. There is s a disposal
reservoir where the water is injected to and the remaining goes alongside with the
hydrocarbon. The flow rate determines the thickness of the water and gas layer.
In Gullfaks it is used a separator simulator called Simulink model. It confines the pressure,
density and composition of the flow of water and oil in the separator. If the level of water is
below the outlet then no water will be in the top.

New Separator design

A new design of separator is being implemented in the Gullfaks. The new design resulted due
to the production of sand which was causing many problems such as:
• Clogging of equipment
• Damage downstream system
• Damage water injection pumps and injection wells

• Figure 3: 3-hase separator solid, liquid and gas with a sand handling system.

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 [PHASE 2] December 12, 2014

Advantages:
• 3-phase separator
• Use of less valves and connectors
• Need less intervention ships
• Use of a bypass line for the gas and give more volume for oil-water-sand
separation.
• Ease use of process equipment

The main reason this new separator being used is that it prevents the production of solids
which damages the equipment. Is provides special units, which is in a certain position in a
row in the separator, this combines the water feed for sand fluidisation with suction of the
resulting sand slurry as shown on figure 4.

Figure 4: Illustration of the 3 phase separator with the side for sand removal. (Ref. Image form Aker
Solution website)

3.3 Oil gas and water Treatment

In the hydrocarbon production happens that when having water and gas are present in a
considerably high pressure and low pressure means that there is a use probability of
producing hydrates.

The heavy oil treatment and separation consist of gas, water, oil, salts and solids separation
even though it is a process which nowadays is less complex it is more difficult to deal with
conventional crude oil than with heavy oil. The process of separating the oil happens in a way
that viscosity has to be reduced as a result of high temperature operations and this will
increase the water in oil solubility.

In Gullfaks the oil treatment are taken place using designed crude oil electrostatic
dehydration and desalting system and this is very efficient because it can remove aqueous
brine and connate water, impurities such as water soluble salts and inorganic solids. These

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 [PHASE 2] December 12, 2014

technology subjects emulsified fluids to a high voltage electrical field, the action of it causes
droplets suspended in the oil and it becomes polarised and separate by gravity settling.

The sweetening process consists of removing H2S and CO2 and in the Gullfaks this is taken
place by using an amine plant whereas the gas being generated is disposed of using
incineration. Nearly 2 tonnes of H2S is removed daily by using incineration unit this is then
turned into sulphur dioxide then it is mixed with seawater and sulphur ions are created
naturally. This process is taken place in a safe environmental way with no risk. Apart of
amine it is also used membranes and glycol based systems.

Figure 5: Sweetening process diagram explain how the gas goes into the amine absorber and
after various stages goes out sweet.(Ref no4. Image form Aker Solution website)
Water Treatment

The Gullfaks is a mature field and the water cut increases steadily when the separation process is
done the liquid haves some remaining oil. In this field for water treatment is used hydrociclones
combined with different coalescing technology. This water containing oil is well cleaned before being
discharged to sea or reinjected. (Ref. list n.4)

Water Injection: Gullfaks

The water injection method is used to increase the oil recovery since it is a mature field but a big
challenge on this is to filtrate the impurities and eliminate H2S content in the sea water.

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 [PHASE 2] December 12, 2014

4. HYSYS Simulation
The simulation was undertaken using the component data and specified conditions to meet
sales requirements. The final hysys diagram shows all the streams until the final outlet of oil
and here will be shown tables with the feed in ( Hydrocarbon and Water) both going to the
mixer and then will go to the first separator after being heated.

Oil Feed at pressure of 4 bars and temperature at 60 °C, the gas reinjected at 120 bars and
50 °C.
Components used as feed in are in the following table:

Table 1: Component list, mole fraction, molar flow used as feed in shown in this table.

Calculation: Oil and water flow used in the HYSYS.

Production data
P = 1901 kpa
T= 18 °C
Volume flow (ID 3021399) = 144000 stb/day
Water Cut = 14%
Conversions
1 day = 86400 s
1 sfd/day=5.61 scf/day
HYSYS Results
Volume Flow at standard conditions = 953.9 m3/h
Water Cut Formula
Substuting the values *100

Vw = 23441.860465 stb/da calculated by HYSYS in standard conditions Vw= 155.3 m3/h

During the addition of components to HYSYS simulation the C12+ had to be added in a
different way by selecting the hypothetical while the others were added normally has pure
components.

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 [PHASE 2] December 12, 2014

C12+ has a molecular weight of 300 mol/kg and a density of 800 kg/m3 and its boiling point
of 349.22 °C. Then hysys calculated the critical properties as P=1134kpa, T=502.9°C.
Table 2: Water feed stream table going to the mixer.

Table 3: Material stream data.

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 [PHASE 2] December 12, 2014

4.1 Mass balance and energy balance calculated on from hysys and excel.

The mass and energy balance had also carried out in order to meet the conservancy of the
mass all feed going in must be equal to the ones going out. As shown on table 4 the total
amount of energy that went in was -3.991e+009 kj/h and the same was going out. Similarly
with the mass total amount going in 8.281e+005 kj/h and going out 8.281e+005 kj/h.
Afterwards the other tables 6, 7 and 8 showing the balance for all components.

Table 4: Energy balance.

Table 5: Mass balance in the valve.

Reservoir Fluid Reservoir Fluid 2
In Out
0.000718 0.000718
0.001986 0.001986
0 0
0.196808 0.196808
0.015383 0.015383
0.012932 0.012932
0.003254 0.003254
0.006635 0.006635
0.00355 0.00355
0.003465 0.003465
0.013523 0.013523
0.006677 0.006677
0.011326 0.011326
0.013692 0.013692
0.012847 0.012847
0.019355 0.019355
0.098425 0.098425
0.579421 0.579421

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Table 6: Mass balance around the separator

MASS BALANCE IN THE SEPARATOR 2
Oil 1( mole fraction) Oil 2 (mole fraction)
IN OUT
0.000062 0.000062
0.001066 0.001066
0 0
0.041899 0.041899
0.013043 0.013043
0.025629 0.025629
0.009946 0.009946
0.022413 0.022413
0.014667 0.014667
0.014832 0.014832
0.065057 0.065057
0.031184 0.031184
0.055304 0.055304
0.066833 0.066833
0.062637 0.062637
0.094056 0.094056
0.480711 0.480711
0.000659 0.000659

Table 7: Mass balance of feed in oil and water, feed going out export oil, heavy product 1,
residual liquid, water and export gas.

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 [PHASE 2] December 12, 2014

4.2 Sensitivity Analysis: Separator Temperature (Parameter 3)

On the sensitivity analysis a case was opened to analyse through hysys the effect of the separator
temperature by varying the temperature at a certain range and molar flow rate of the gas and TVP of
the oil.

In order to do that the objects with their variables chosen were:

1- Gas Compressed – Temperature ( Independent)

2- Top gas – Molar Flow
3- Heavy product - Molar Flow

Temperature variation chosen numbers for the independent variable:

Low bound = 43 °C / High Bound = 122 °C / Step Size = 30 °C

This study resulted on the following graph plots:

Graph 1: Compressed gas temperature against Top gas molar flow.

Graph 2: Top gas molar flow against the heavy product molar flow.

The figure in the first graph shows that the molar flow increases until reaching the peak at
80 °C were the temperature stops increasing. While the top gas stabilized on nearly 1560
kmole/h. The graph 2 shows the increase in top gas molar flow as the heavy product
decreases from the highest value of 6.000 kmole/h.

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Discussions

 The Gullfaks is a very challenging field and due to being mature it faces many
problems such as pressure drop, storage space in the platforms and others. On the
other hand, efforts are being made to improve it and increase production rates. This
will pass to implementation of new separators and new technologies to enhance oil
recovery. All investments in Gullfaks are worth since the oil from there has good
quality and an API of 36 sweet.

 The HYSYS simulation was done in the specified co0nditions using 3 mixers, 2 3-
phase separators and 4 second stage separator used mainly to for the gas separation. 2
valves were also used to due to pressure drop, 2 heaters and 4 coolers. The inlet feed
denominated hydrocarbon feed and water feed both went through a mixer, a heater
and valve to the separator 1 as reservoir fluid and from there separation happened. On
top the gas and down oil and water at the bottom to be recycled. The gas was cooled
and condensate as the water went for further treatment. The hysys simulation enabled
a final product of export oil at the desired conditions of 100kpa at 37.8°C. The gas to
be exported at required conditions of 50 °C and 120 bars while the final oil is at 60 °C
and 400 kpa.

Conclusions

To conclude, the production facilities are the main character in the industry because it
manages the entire process of the oil exploration. In the Gullfaks most of the facilities and
equipment were constructed over 20 years ago and are currently being renewed. In order to
increase oil production a new subsea separator is being implemented which will separate
solid, gas and liquid letting more space for storage in the surface facility.

The HYSYS simulations has showed effectively the process of separating the oil, gas and
water shown on the block diagram aiming the desired conditions to export. Finally the
sensitivity analysis has shown the effect of varying the temperature in the separators and the
molar flow rate behaviour.

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 [PHASE 2] December 12, 2014

References

1- https://www.akersolutions.com/Documents/Drilling%20Technologies/Process%20Sys
tems/Processing_solution_brochure.pdf (accessed on 7/12/2014)

2- http://www.offshore-technology.com/projects/shearwater/ (accessed on 8/12/2014)

3- SPE paper, FIIS de-water test at Gullfaks field, G. S. Eidsmo, B. Johannesen. SPE
November 2011.

4- https://www.akersolutions.com/Documents/Drilling%20Technologies/Process%20Sys
tems/Processing_solution_brochure.pdf ((accessed on 8/12/2014)

5- Dr. Andrew Fergusson-Rees Lecture Notes, Production Engineering, LSBU

2014/2015.

6- http://www.statoil.com/en/OurOperations/TradingProducts/CrudeOil/Crudeoilassays/
Pages/GullfaksBlend.aspx [Accessed: 5/12/2014].

7- Norwegian Petroleum Directorate, 2013, Publications/Facts [Online] Available from:

http://www.npd.no/en/Publications/Facts/Facts-2013/Chapter-10/Gullfaks/ [Accessed:
2/12/2014].

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Attachment: HYSYS Simulation final Block Diagram.

LSBU |The Gullfaks Oil and Gas Field 16

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