FIELD Site Vist Report-WET 2012-I Gede Suryana S

FIELD‐SITES VISIT REPORT WET TOTAL E&P INDONESIE PROGRAM BATCH 1 2012

TRAINEE:

I GEDE SURYANA SAPTAWIRAWAN / L0385489

TOTAL E&P INDONESIE BALIKPAPAN ‐ 2012

Field Site Visit Report‐WET TOTAL EP Indonesie‐I Gede Suryana S. | 2

INTRODUCTION

WET program is the new training for the future TEPI well engineer. As the engineer, the main job is designing and calculating the program, both drilling and well intervention program. To have a logic and effective program, engineer must have the field knowledge. Not only the geological data and information about rock formation, but also the real and actual condition in the field, including the knowledge about the equipment, the Service Company, etc.

The site visit program can be the media to insert that culture. The knowledge about the whole production area make the trainee know more about their company and expected to know about the team work mechanism inter‐department in TEPI. Sharing experience from the senior employee can be a motivation and a very good lesson to face the work in the future. The last, the trainee can feel the work atmosphere in TEPI both in office and field, and learn about the company culture to increase the soft skill for the trainee.

OBJECTIVES

1. WET trainee has a good knowledge about the whole business processes in TOTAL EP Indonesie.

2. WET trainee has a general overview about their job in the future.

3. WET trainee understands about the inter‐department relation related to their work.

TABLE OF ACTIVITIES

NO DATE AREA LOCATION DESCRIPTION

1

28/04/2012 SENIPAH PPA

Pechiko Processing Area is the gas processing facility of TOTAL EP Indonesie which covers the Pechiko and South Mahakam production field/well. There are about 123 wells in both of the fields, going to be 7 platforms that are connected to PPA. Those are consist of Medium (MP) and Low Pressure (LP) channels. Each of them has a different treatment.

LP channels go to LP Separator first. The separator system in this processing area use Slug Catcher[1] and Tube‐Separator [2] to separate the gas from the slug, caused by the different velocity of each fluid‐phase pass through the same pipe that has curve shape in some areas , from oil and of course from the water. The Oil and Condensates that is produced from the separator will be transferred to TLA (Terminal Loading Area) to be saved in the tank. The water goes to water treatment unit, which will treat the water to be good‐environmental condition.

After the LP gas passes the separator, it will go to the Medium Pressure Compressor (MPC). MPC will change the pressure level of the gas, from LP (5 ‐7 Bar) to MP (20 ‐ 22


Bar). After reaching the expected pressure, the gas will go to High Pressure Compressor (HPC) together with MP gas that has been separated from oil and water in MP Separator. All of the gas will be converted to HP gas (55 ‐ 60 Bar) in HPC. As the effect of the increasing pressure, the gas temperature will also rise. This will support the treatment gas process. After being the HP gas, these gases will go to the Gas Treatment Unit. In this unit, the gas is treated to be a dry gas. That means eliminating the water element in the gas as low as possible. This process use absorption‐method with Glycol as the material to absorb the water from the gas. In this unit, the moisture and properties of the gas will be controlled based on the customer’s specifications. The pressure will be conditioned too, therefore the gas can be transported to Badak as the main customer of the company.

TLA

Terminal Loading Area is located near the PPA. It is the liquid storage facility of TEPI. It Covers all of liquid (oil and condensate) products from all production fields under TEPI after processed in TPA (Terminal Processing Area). In this TLA, there are utilization facility and the mixing facility for some special customer‐requested liquid. The liquid is mainly come from the separator system in every processing area owned by TEPI. The liquid will be sold in the “oil supermarket” because TEPI does not have long‐term contract for oil and condensate selling. The best quality and of course the most expensive oil is from Bekapai, the second one is Handil Mix, and the last is oil from Handil.

TLA has 6 tanks to store the liquid. 2 tanks service Handil area products, 2 tanks for Bekapai area products and the last 2 tanks store Condensate products. Each of the tank has a capacity about 50000 barrel. It uses floating system, which means the cover of the tanks rise up and down according to the liquid level inside it. This system is used to minimize the air and gas contained that used to be stored above the liquid in the tank. TLA is connected to the manifold and the pump to transfer the liquid to the tanker at the Jetty. It also has a Pig Launcher System [3] that will be useful to clean the pipe or to border 2 different liquid when transferred in the same system.

TPA

Terminal Processing Ares is the liquid processing facility of TEPI. All of liquid product is processed here before stored in TLA.

TPA get its input from CSU (condensate stability unit), therefore the entire liquid product from all production area going to CSU first and then come to TPA.

In this area the condensate, produced from the separator system, run in to 3 phase separator. The separator will separate the gas contained in the condensate. This separator system also called Degasser. These gases occur in bubble


form inside the condensates, called Cavitation. This condition is not good for the pump and confusing the metering system. So the gas will be removed from the condensate. The gas that is formed from the process is sent back to PPA for treating. After that, the clean condensate and the oil will be stored in TLA. Waiting for the customer.

CSU

Condensates Stability Unit is TEPI’s facility where all of the unstable condensates comes from others processing unit. ( Senipah is the only one processing area for liquid in TEPI, so it will receive liquid from the whole processing area of TEPI in East Kalimantan district ). Condensates is a low‐density mixture of hydrocarbon liquids that are present as gaseous components in the raw natural gas. It is usually brought by the oil or gas when it is lifted up in production line. Condensates is very unstable, because It is presence as a liquid phase depends on temperature and pressure conditions in the reservoir allowing condensation of liquid from vapor. It changes to vapor easily. Therefore, in this unit it must be stabilized before treated in TPA. To keep it stable as the liquid, and eliminate the gas from it.

CONTROL ROOM

This room is like “the brain” of the whole processing activities in Senipah Area including PPA, TLA, TPA and CSU. From this room all of the activities and condition on the field are inspected. From this room too, the command comes from.

The room is installed with a lot of monitor displayed the data and the condition which describe the movement of the process. The monitor show the condition of the flaring system when the control room is visited. Because now, all activities in processing area mainly have the electronic control system and connected to control room by transmitter system. The control room can manage the process in the area, if needed, by pushing the button on the control panels.

The operator can control the valve, control the pressure, launch the pig, control the pumping system, executes liquid mixing process, and drive the oil and condensates to the tanker.

Those processes can be safer, because less people are involved in the risky process in the field.

This control room is placed in the main office of Senipah area and runs 24 hours a day. Using computer‐based control system that connect to the hydraulic and pneumatic system as actuator, the whole actions are controlled by the 3 main panels (each of them handle different processing areas) and operated by 2 operator in 2 shifts.

WAREHOUSE

In Senipah Area, TEPI has a warehouse area. It is under the command of MLO, especially the logistic division. It is utilized as the storage center of the logistic needs of the production process in PPA, TLA, TPA CSU, and A few things for drilling division.


The storage area is divided into 2 general area. Open area and the storage building. The open area consist of the pipe yard, where the stock pipes for production line and several tubing and casing for drilling placed, the chemical storage, the special building to store any chemicals that is needed in production. It is special designed with the high security level to avoid the accident. Only authorized officer can enter the building with a complete PPE (Personal Protective Equipment) and breathing apparatus. It the open area, there are also the place for the special garbage, like electronic thing, the radioactive waste and the unused machine/engine. The warehouse also has the packaging and maintenance facility, to maintain the stock of the material so it will be in good condition if needed to use.

The storage building is the place to store the components, spare part of the engine, and small‐sized equipment. It has some long and great shelfs /cabinets to store a lot of equipment which have a unique number for each of them. The number is the method for manage the tool/equipment, so it will be easier to trace the location, to know the number of the stock and for the database

All of the materials and equipments are sorted by its utility or its company/manufacturer.

2

29/04/2012 Handil Area

WLI AND DRILLING

WORKSHOP

Handil Dua Base is the center base of logistic support in TEPI. It provide logistic for the whole activities in Mahakam Delta river, and of course the transportation/ traffic. Not only land transport, but also marine and air traffic.

As the main logistic support, it is attached with warehouse and workshop, especially for drilling activities in Delta.

The warehouse is positioned near the jetty. It consists of the open area, where mainly the pipe for drilling activities stored and the workshop.

Many types of drilling pipe are stored there. Such as Tubing, casing, drill collar and any other drilling‐related materials. It also use as the temporary storage for the idle Christmas tree, that is removed from the maintained‐well. All of them are sorted neatly by the size and dimensions. It usually called pipe‐yard.

It also have a chemical storage facility, a large equipment storage facility, and the maintenance facility to take care of the pipe (because stored in open area, it makes the corrosion occurs on the pipes). The role of this warehouse is very important for the entire activities in the Delta, all of the material and equipment that is required in the activities have to transfer to this warehouse from its manufacturer, stored there a while, and distributed to the precise activities location (generally, the drilling activities are in the isolated area, so it do not have a storage facility).


Well Construction and Completion Workshop To support the well construction / drilling activities

around the Mahakam Delta, there is a workshop in Handil Dua Base. Its main role is to provide the needed of the drilling activities as soon as possible. Including the tubing, casing, drill collars, jointing pipe activities, and others.

Drilling activities mainly execute by Service Company. They are also responsible for their needed by their self. But occasionally there are some troubles in the field, and they are lack of supplies, the warehouse will use the stock in the warehouse to accomplish it. Sometime, they also need to cut the pipes or connected two pipes to meet the specifications of the well, the warehouse alsot can do the job.

The main function of the workshop is the testing facility. It has a testing‐bunker to simulate the condition of the well, including the pressure and the flowing fluid, to the equipment. The bunker used Helium and Hydrogen as the fluid before, but according to the environmental regulation, now it use Hydraulic system to detect the leakage on the pipe.

The workshop is led by the well‐experienced employee , Mr. Shobari

Well Intervention Workshop Well intervention, known before as well service, is a very

important activity in this business due to the decreasing of mature well quality. To support the important job, especially for the activities in Delta, The Well Intervention Workshop was established in Handil Dua Base.

The main job of this workshop is manufacturing, supporting and testing well intervention’s equipment. This place is also divided into two section, the equipment workshop and gas lift laboratory.

The equipment workshop is the place to aim all roles of the workshop. This workshop employs some engineer and technicians to manufacturing and supporting. Manufacturing means design and create supporting tool to execute well intervention program. According to unique characteristics of some wells, it need special tool to doing the action. This function also has a close connection to service company. For executing the well intervention program, TEPI use service company including their technology and tools.

Before implementing the tools and technology, the service company will order some equipment from its headquarter/manufacturer and transiting it for a while in this workshop because they do not have any logistic or marine support to distribute it. Seeing that condition, TEPI make some policy to the service company to test their equipment in this facility. The workshop have an artificial platform to simulate the well condition, therefore, they must assembly


and setting up their equipment then test it. During this process, TEPI crews can study about the technology and the product, like technology‐transferring session (every service company have their own technology and developing, so a lot of thing and developed equipment can be learnt).

During the visiting session, this workshop prepared some DHSV [4]. The testing time also use to ensure the equipment work well, so the program will run effectively.

The Workshop also support the lack of drilling tool, needed by the rig, in small amount, and the last essential job is obtain the ex‐drilling equipment, that can be recycled, like warehousing activities.

Occasionally, the ex‐drilling equipment arrive not in good condition, the workshop can make a justification, and repair it, if required and able to do.

In Gas Lift [5] laboratory, there are several tests to ensure the tools that used to the gas lift process can be used in the tubing. Gas lift is commonly type of artificial lift to help the oil lifted from the reservoir. It uses one type of nozzle named SMP (Side Pocket Mandrel) as the gas ways from the annulus to the tubing. In the lab, they test the function of the SMP using pneumatic system.

BSS‐PENDINGIN

Pendingin Area is the drilling liquid installation of TEPI. It is operated by Halliburton, and exclusively services the operation in Mahakam Delta.

The facility was established in 2006 and consists of 2 main sections, Baroid Surface Solution and Liquid Mud Plant. The main job of this facility is to produce the mud, supply the water based mud material for drilling (done by LMP), to process the cutting from rig to be more environmentally accepted to be wasted, and extracts the oil base as the basic material of OBM/Oil Base Mud (done by BSS).

The need of removing hydrocarbons from drilling cuttings for environmentally acceptable disposal of the cuttings was recognized in the early 1990s. Indonesian government stated the maximum

hydrocarbon contained in cutting before wasted to the sea is 1% or 10000 ppm. TEPI as the environmentally‐care company ruled the maximum number of oil/hydrocarbon in the cutting is 2000 ppm, lower than the government.

To remove these hydrocarbon‐based fluids from the cutting, BBS Pendingin facility use a technique called thermal desorption. Using TDU (Thermal Desorption Unit) [6], it processes the cutting and extracts the oil base that will be used to make a fresh mud in the future operation.

In BSS, the whole mud comes from the rig by the barge. Before processed, the mud enters the pit waiting for the next step. First, the crew gets some samples of the mud to be tested in laboratory. This facility has 2 laboratories,


Halliburton and third party services, ALS. The sample called retord is tested here to the material and properties of the mud.

TDU need special mixture between water, oil and other material to be operated well. Therefore, if the mud does not reach the exact mixture, they must be treated first. Centrifuging in LMP is the common treatment method.

The second step is transporting the mud from the pit to the TDU. This step automatically done by the conveyer belt.

The next step is thermal desorption by TDU. TDU consists of rotating chambers, and condenser section.

The spinning chamber formed as the drum. It has 2 chambers for optimum product. The first chamber has maximum temperature 10500 F and the main chamber has 11500 F maximum temperatures. Avoiding explosion accident in the chamber, the drum is planned to segregate the mud inside from the outer‐air , which is contain oxygen (remember the fire‐triangle, in the drum, there are heat and fuel/oil contained by the mud, so eliminating the last element, oxygen, is expected to decrease the possibility of the explosion)

The mud run inside the rotating heating drum from the first chamber to the main chamber and after that the solid cutting will go to the disposal tank. During mud run through the drum, the liquid will evaporate through the gas‐way at the top of the drum. The gas‐ways are present in every chamber to catch the vapors. After passing 2 rotating chamber, the cutting expected to be dry, and contain oil maximum 2000 ppm.

The vapor comes into the condenser unit by the pipe. The condenser consists of 3 tanks. First, vapor come to the oil tank. In this tank the vapor, which contained some oil, will be sprayed by oil to condense the oil. This oil will be stocked as oil base. Then, the vapor will go to next tank. In this tank, vapor is sprayed by water to condense water. This water goes to water treatment system. The output will use as hydrant system for fire emergency system, and the rest disposed to the sea. Even passing 2 condensing process by water and oil, some vapor still have a little water and oil inside. Therefore, the third tank exists. In this tank, the rest of vapor is sprayed by the water again, to control the oil and water in the vapor. The liquid will go to the water treatment system and disposed at the end.

The rest little vapor will release to the open air because it just contain a little number of hydrocarbon materials. The dry cutting will be disposed on the sea. The government has determined the authorized location to dispose it. Every oil company has their each location to reduce the bad impact of hydrocarbon on the water sea.

This facility is fully controlled by Halliburton under


supervision of TEPI. There are 2 representatives of TEPI. It also has ALS laboratory to test the mud. It is used the make a fair testing result for TEPI, because if the cutting still contain hydrocarbon/oil above 2000 ppm, the cutting must be reprocessed freely.

LMP‐PENDINGIN

All drilling operation will require a blend of chemicals which are mixed (drilling fluids) commonly known as drilling mud,

It is used in circulating system of the rig. The liquid has a very important role in drilling activities. Drilling can be simplified as the activities to dig a deep hole on earth. Because its depth, it will run through rock formation and porous rocks. To keep the rock formation do not fallen, the higher pressure must be applied inside the whole the press the formation back. This mud is the material to do this job. Therefore the mud must have a specific density to ensure the pressure, a specific viscosity so it can be well circulated in the bore hole. It also used to lift cuttings from the well, sealing permeable formation until the casing is cemented in the well bore, cooling and lubricating the drill bit.

Drilling mud consists of a continuous liquid phase to which various chemicals and solids have been added to modify the operational properties.

Depending on the geological formation, environmental, application and well objectives, the drilling mud system are either water based or oil based. The water based commonly used in top section of the bore hole, because this section has more unstable rock formation than the lower section.

For environmental reasons and restriction especially in land drilling operation, the drilling mud must be handled in an environmentally safe condition. Therefore instead of storing and mixing the chemicals at individual rig site, majority of the oil companies are now adapting to have a central Liquid Mud plant, where the storage, handling and mixing and liquid storage are kept.

In LPM Pendingin, the facility only produce oil based mud that will be sent to the rig. Water based mud usually made in the rig, because the main material, water, is easily obtained in the swamp. The LMP only supply the raw material, like Barite and some chemical if needed.

The Oil base mud is made from the oil, water and other addictive. In this facility, the oil that used to make the mud is come from the recycled oil base. The original imported oil base only use as the backup, if the recycled oil base is running out. To mix oil base and water, some emulsifier is used. To meet the weight specification some addictive is needed. The common uses addictive for OBM are barite and calcite. After all of the material is obtained, the process to make the mud is started, there are filtering, mixing


processes, centrifuging, and adding chemical at the end. The processes can be simplified like this. First, the mud from rig is come. It goes to the pit like the processes in BSS, it will be filtered by 2 shelshakers and run into centrifuge machine. The solid output of the centrifuge unit goes to TDU, and the clean mud got to mixing tank. In the mixing tank, the refreshing process is executed by inserting some chemical like barites, calcite, and gel tone. After being the fresh mud, it will move to the storage tank, and ready to use.

TEPI supervising the whole process by give some requirement form to the LMP, including the volume, the density, the rheology, etc. After finishing composes the mud, some sample will be reserved to the ALS laboratory, to examine the properties of the mud. After receiving approval from the company man, the barge will take it to the rig.

This facility has a warehouse and 4 tanks to store the mud.

3

30/04/2012 CPA HANDIL WELL CLUSTER

Handil is the oldest production area of TEPI. In this area, there are about 660 wells, both producing and unproducing.

Because founded for a long time, many developed wells are made there. Several adjacent wells make a well cluster.

During the visiting time, one of the well clusters in Handil area was showed to know the real shape of the oil well.

The cluster consists of about 8 wells, mostly oil well with free gas type. Every wells has its own platform, but sometimes in one Well Platform [7] there are 2/3 wells for efficiency reason. On the platform‐surface, A well consist of a well head, also known as Christmas Tree [8], the production line, gin pole (the yellow high bar for hanging the intervention well tools), and control panel.

Christmas tree is like the cover of the well. Made from thick steel to treat the pressured fluid from bottom, It has some valve as safety mechanism for the well. The master valve and wing valve. The master valve consists of lower valve, upper valve, and swab valve. Lower and upper valve is normally‐open valve and the swab is normally‐close valve, when in production session. The swab and lower are usually controlled manually by hand, and the upper is driven by hydraulic system/pneumatic system.

The oil well head have 2 strings inside, the lower and higher string. It is possible to gather the oil from two different layer in subsurface.

The swab valve is only opened when the well intervention department wants to make some intervention to the well, like testing, snubbing, and others. Before inserting their tool by the string/tubing, they must open the swab valve first. The well operator, who accompanied us in the visiting, said the order of safety action when gas leak


happened. The first valve to be opened is lower valve, if the gas can pass the valve, the upper valve controlled by hydraulic will automatically close. If the passing (the gas can pass through the valve/ or safety valve failure) still occur, the last defense is DHSV in the tubing.

All wells in Handil area are mostly mature oil well, therefore the pressure is categorized as low pressure (LP, around 7 bars). At the first, the well is dug, it has a medium pressure around 20 bar, but it decreased in line with the maturity of the wells.

The wing valve is connected to the choke system (system for controlling the amount of the oil flow through the production line, controlled by hydraulic/pneumatic system) and production line.

Several wells product in same cluster go into manifold, to be merged into single higher diameter production pipe to the processing area. In this manifold there are 2 production pipes for MP and LP, so the product will be categorized in the manifold. In this manifold, there is also the test head, use for testing well purpose.

The articial lift mechanism is needed for the mature oil well to keep up its productivity. In this cluster, there are 2 types of artificial lift applied to the wells, the gas lift (pumping the pressured‐gas to the annulus to help lifting the oil in tubing) and ESP (electrical submersible pump, placing a centrifuge tubing‐shape pump inside the tubing to help lifting the oil).

Beside the oil well, this cluster also has a gas producer well and water injection well. Gas producer well have two main utilities, to get the gas for product and as the gas supply for artificial lift mechanism and the gas instrument for pneumatic system. The well surface structure between the oil well and the gas producer is comparable, but the gas producer and gas well in general, only has 1 string in their wellhead because using the tubing‐less architecture. The gas produced from the well go into Scrubber, the device to split up the gas from water and condensate contained. Because it has a high pressure, the gas will be merged with the pressured lifting gas from the compressor in CPA going into annulus and execute the gas lift system. These gases will be brought by the oil to the CPA.

The water injection well, is the well for inserting water to the reservoir. It is one of the HEOR (Handil Enhanced oil recovery) methods. This well is deeper than the oil well, because the water layer is the bottom layer. The water is expected to push the oil, which has a lower density than the water, to go out from the reservoir to the oil well. To supply the water needed in the water injection processes, the water well producer is produced. In Handil area, there were 8 water‐wells, 7 for supply HEOR, and the rest is for daily use


potable water. The water well only has about 300 m depth.

CPA PROCESS AREA

Central Processing Area is the processing facility for the product of Handil production area. Handil area has about 660 wells, mostly oil well free gas type. Only 374 wells are active. 8 string Medium pressure, and 123 string Low Pressure well (using gas lift. Because Handil is the oldest production area in TEPI, almost well in this area is a mature well, and need to be maintained.

Handil CPA Field characterized as oil field with some free gas. The main product of this CPA is paraffinic oil with pour point at 260 C. The reservoir is deltaic multilayer sand reservoir type. It has average oil production capacity 18910 BOPD (Barrels of Oil per Day) and gas 60 MMSCFD (Million Metric Standard Cubic Feet per Day )

CPA is divided into several sections. Such as power generator, fields separator, LP separator, LPC, MP separator, HPC, contactor, Oil and condensate pumping system, HEOR, Hydrocarbon Water Treatment System.

Power generator plant is the main electrical power source for the CPA. Consisting of 2 Gas Turbines, which has 1.5 MW capacities each. The electrical will go to the switchgear after generated to be distributed in the CPA.

The Handil area has 3 production zones, M1, M2 and M3. In every zone, there is a manifold for collecting the oil from the wells. Before insert the CPA, on each manifold zone, the oil is treated in Field separator to reduce the water. This process will make the CPA compressor load lightly. After separated in the manifold, M1 and M2 will go to LP Separator in CPA, and M3 will go to MP Separator.

LP separator handles the crude oil from M1 and M2 zones. CPA has 2 3‐phases LP Separator. The gas will go to the LP Compressor, the water goes to Water Treatment System, oil and condensates are driven to pumping system.

Low Pressure Compressor (LPC) is utilized to convert the pressure level of LP gas to MP gas.

MP Separator has similar role with LP separator, but the input is from M3 zone and the output will go to the HPC. CPA has 2 2‐phase LP Separators.

The gas from LPC and MP separator will be merged to one line and will be divided into 2 lines, HPC and HEOR. Most of the gas is going to the HPC (High Pressure Compressor), compressed to HP gas (around 50 bar) to meet PT. Badak’s requirements and able to transporting. The rest gas will go to Handil Gas Lift Unit (HGL) because HEOR is stopped operating at 2007.

HGL consists of Compressor to compress the gas until rich the proper pressure for gas lifting activities, also considering the pressure loss when transporting. After compressed the gas will go to the manifold and distributed to the wells with gas lift.


The gas from HPC will go to the contactor. Contactor is the tube where the water absorption process is applied to the gas by spraying glycol to the gas. After reach the water contained specification, the gas will go to the PT. Badak as the Customer.

Pumping system receive oil and condensate from all separator. And pumping the oil and condensate to the CSU in Senipah. It has 4 pumps work parallel to do the job.

Water from the separator goes to the water treatment system. It will be processed to be more environmentally accepted before disposed to the sea.

In general CPA has a similar activity with PPA, but CPA does not have Slug Catcher.

CPA CONTROL ROOM

This room has the highest authority to manage all the activities in CPA. It has the same function with other control room. Using the computer based controlling system; the whole activities in CPA can be controlled by the operator in charge, 24 hours in 2 shifts.

5

02/05/2012 CPU GTS AND GAS WELL

Gathering Testing Satellite is field testing facility for gas well in Tambora and Tunu production area, production area covered by CPU. In Tambora and Tunu, there are 5 GTSs; GTS 1, GTS 2, GTS 2X, GTS 3, and GTS 4. All of them can be remote from the control room in CPU.

GTS consists of manifold gas well unit and testing facility. The manifold role ids for collecting the gas from several gas wells and connected to TCP in CPU by trunk line. Before going to the trunk line, the gas will be directed by the switching line either go to the production line or the testing line.

In GTS, there are separator, KO drum, metering instrument, and CCVT. The GTS only can test 1 well in the time. So the role of the switching unit is very important to ensure the gas that will be tested is from the selected well, not from the other.

In common operation, GTS only tests the flowing rate of the gas for each well. If needed to know more about the properties, the test can be done later in laboratory facility by taking some samples from the GTS.

In the testing time, the switch will allocate gas from selected well to go to the separator. In this separator, the water is eliminated from the gas. The water will go to the some tanks placed under the platform. The type of the separator is different between the whole GTS. GTS 1, 2 and 2X have 1‐phase separator, GTS 3 and 4 have 2 phase separator. The type is chosen by the gas characteristic from every GTS. If the gas rich in fluid (condensate and water), it will use 2 phase, but if contain only a little amount of liquid, 1 phase separator will be used.

Then the gas goes to the metering tool, to be measured. The Flowing rate data will be acquired and sent to the


control room. The flowing rate will represent the integrity of the well.

KO drum (Knock Out Drum) has a same function with Separator. It use as the backup for the separator, if the separator failure. The GTS also has a venting system to release the gas to open air if the emergency/critical condition happened, like over pressure in the separator and KO drum.

GTS is powered by electrical power generated by CCVT (Closed Cycle Vapor Turbogenerator). It works alike the steam generator. By combusting the gas to get the heat and boil water. From the boiling water, the vapor will be used to moving the generator and generating power for the GTS.

This unit is dangerous for the GTS, because it have combustion processes inside. Therefore, CCVT is positioned in the room with positive pressure (the pressure of the room is higher than the open air and the gas pressure), so the gas can be able to enter the room.

After visiting GTS, the gas well adjacent to GTS would be the next objectives. As mentioned above, gas well has similar structure with oil well. But only has one string because of the Tubing‐less architecture. The wellhead is connected to the choking system before go to the production line. The choking system is the method to control the gas output of the well.

CONTROL ROOM

Because the shut downing processes in CPU, the visit to the CPU was cancelled. But, the visit to the control room is expected to cover the information of the CPU.

Control Room in CPU is more complicated than the other, because it handles several facilities, such as CPU, GTS, and TRF (Total Receiving Facility).

CPU itself consists of CPU 1, CPU 2, TCP, NOWT, STP 1, STP 2, and STP 3.

CPU is initially designed to handle HP gas product, but in line with the age of the well, the pressure is decreased to MP, moreover LP for the mature well. So the HP separator in CPU 1 and CPU 2 are idle. They just doing liquid processing now before the liquid sent to the Senipah.

For handle the MP gas, TCP (Tunu Compressor Plant) was established. TCP has MP separator and HP compressor to convert the gas become HP gas and sent to TRF. In TCP, there is also gas dehydration facility and of course the metering unit to measure the amount of the gas exported to PT. Badak.

To Handle LP gas well, SPU is built. There are some utility to process the gas to the MP gas and sent to the TCP in CPU.

The central process of the gas treatment is in TCP. TCP is connected to 2 channels, TMP 1 for MP gas from the well with 30” diameter pipe and TMP 2 for MP gas from the SPU


with 36” diameter pipe. Totally, CPU and SPU can produce average 1300 MMSCFD of gas.

NOWT (New Oiled Water Treatment) receive the oiled water from the MP separator, and then treat the water before wasted. It is forbiden to dispose the water, because it contain hydrocarbon.

STP is equipment placed in a pipeline for inserting or retrieving a pipeline scraper (pig).

All of the products are sent to the TRF for metering purpose together with the gas from NPU. TRF is fully controlled from the CPU control room. It has a flaring facility, in case overload/ overcapacity.

KHARISMA BARGE

The well intervention activities are the important job in TEPI. It maintain well’s integrity by make an intervention to the well.

The well intervention department has 3 main functions; first, testing the well productivity, second, designing and executing well intervention program, and well data acquisitions.

To support the activities, almost 33 barges are operated. The barges contain the specific equipment for doing special operation.

Kharisma is one of the well intervention’s barges. This barge specialty is electric line operations, especially perforating and data acquisitions.

This Barge is operated by Schlumberger as the service company under supervision of TEPI representative (company man).

When visiting time, this barge is positioned in TN‐AX148 well and preparing to set the casing patch in the tubing. This operation applied because after the perforating operation in the well, there is no gases go out but water. If it ignored, the will be abandoned itself.

In general, the well intervention operation has a similar procedure. First, slick line operation, testing and setting up the tools, then data acquisitions, matching the planned data with the actual data, and acting the operation.

Slick line operation is inserting a special tool at the edge of the slick steel cable to clearing the well. The main challenge of well intervention operation is with the pressure, so to attach the tools need special equipment named PCE, Pressure Control Equipment. The device function is to hold the pressure from bottom by applying the higher pressure from the top of the well. This device also can isolate the borehole or tubing from open air. Before attach the slick line unit, the unit must be tested with 5000 Psi pressure in 15 minutes, then the well cap must be removed. Using the gin pole and crane system, the unit is attached to the well by the string. After that the pressure is applied to the unit, and the crew will open swab valve. The clearing operation will be


started. After the clearing operation, the electric line unit must

be tested in 5000 Psi too. In Kharisma barges, the PCE in Electric Line unit using Flow Tube method. It uses grease as the pressure media. The minimum pressure applied must be 1.2 times higher than the well pressure, but in the actual operation the applied pressure is around 1.5 times. Electric line operation is inserting the special tool with a conductor/wire line that can send electrical current to control the tool down hole from the surface. The line not only used as the hanger but aloe the control line. The Electric line unit can use to perforation and data acquisition.

After tested, the electric line unit is attached to the well in the same way like slick line unit. For data acquisitions, CCL (Casing Collar Locator) and Gamare Method commonly used. Gamare is more precise than CCL but need extra cost.

After get the actual data, then matched planned data with the actual one is needed to ensure the condition of the well and right location for the action. Then the operation can be done.

The specialty of this barge is perforation operation. Perforation is the method to connect the production string with the reservoir by making a hole using explosions. The perforation operation use electric line unit to control the detonator. There several types of gun carrier (the tube to carry the explosion material, and functioned as a gun down hole) such as Strip Gun and HSDG (High Shot Density Gun). Strip Gun is chosen because of mobility and restriction characteristic.

6 04/05/2012 Mahakam Delta

MAERA RIG

Drilling Rig is the most important equipment in drilling process. It is a place/machine to place all drilling tools.

One of the rigs operated in TEPI is Maera. It is Swamp Rig types owned and operated by APEXINDO.

It looks like a giant barges with a high tower on it. All of drilling activities central there. The Crew is consisted of APEXINDO for the driller position and the position above it, Brahmana as the subcontractor for the position below the driller like roughneck, painter, etc., Schlumberger for cementing and wire line operation, and Halliburton for the mud operation. All of the crew is led by Rig Superintendent. TEPI place its representative there as company man, to make supervision, an ensure the drilling program run well. The Company Man in charge was Mr. Valentin Lara.

Maera is consists of crew Accommodation, Office, main deck, cantilever, drilling floor, hoisting system, rotating system, circulating system, BOP, and engine room.

Crew accommodation located in upper deck. There are the bedrooms for the crew, office, recreation room, radio room, meeting room and galley.

Main deck is the place for store the material and tools


for drilling. The drill bit that has been used before can be seen there. For this well, two types of drill bit were used. For top section, tri‐cone drill bit was used, considering the rock formation is softer than the bottom. That can be seen the drill bit still in good condition, can be used in the further operation. For the bottom section PDC (Polycrystalline diamond compact) is used, the bottom rock formation is the strongest formation so need the stronger bit. Even use the stronger material as the bit, the last PDC bit, that used to dig the open hole, has broken its teeth.

That cantilever is connected the main deck with drilling floor. Cantilever use as the pipe yard, because the position is near the drilling floor. When visiting occur, the well has been dug, and they prepared to set the tubing up. Before setting up in the casing, the tubing is attached with Centralizer, to help positioning the tubing in cementing operation. There is also some joint pipe with several of length. The pipe is use to mark the perforating location, because have a different length with the other pipe.

Drilling floor is the central place of drilling. It consists of the hoisting system. The system function is lifting, holding and putting down the string, drill bit, and other tools for drilling. This system is built by a derrick as the holder, block and tackle as the up‐down mechanism, and 3000 Hp draw work as the torque source for lifting activities. Block‐tackle and draw work is connected by 1.625”drilling line.

The rotation system use Top Drive System, therefore the bit was driven from the top not from rotating table again. This technology can accommodate rotating and circulating system.

The circulating system uses the technology from Halliburton. Mud pit consists of 6 tanks and managed by mud engineer and pump‐man. They create the mud here. 2 type mud is used, WBM (made from HCL polymer) used for top section and OBM is used for lower section. This mud must keep the stability of rock formation, so it must make weightier than the pressure from rock formation. The weight of OBM is commonly 1.5 SG. It was pumped by a Triplex 3 Piston Single Act Pump.

Power system is consisting of diesel engine that generates electrical power for draw work and TDS. Cementing unit use the technology from Dowel Schlumberger. It has a specific pump, because it needs higher pressure to pump the cement out from casing to outside between the casing and the rock formation. In cementing, some item must be considered, like pumping time and thickening time. To modify them some chemical can be added as the accelerator and retarder.

BOP (Blow Out Preventer) is the safety device to handle kick / blow out from the hole. The BOP in the rig has 4 ramps


1 annular that driven by hydraulic system. The BOP can handle 10000 Psi pressure.

The well‐constructed there use Opti‐slim architecture with 4500 m depth. First they hammed the 24”conductor pipe and drill inside it. Then 10.75”surface casing set to top section, then the 7” production casing for the lower section. It uses 3.5” production tubing.

To Monitor the development of the drilling program, a mud logging was acted by the Geoservice. It has a lot of sensor set in every drilling tools, so the movement of the tool, the development of drilling, and the danger coundition can be known and noted.

7 05/05/2012 Tanjung Batu

POSB PETROSEA

Now, the drilling and production activities not just limited in swamp area in Delta. A lot of developed well in South Mahakam will be execute soon. To provide the logistic needs of the off shore platform and drilling activities, TEPI rent logistic service in Petrosea Off shore Supply Base, Tanjung Batu. Including the warehouse, the jetty, water treatment service and Liquid Mud Plant.

It is in strategic location near the sea, not like Handil Dua Base. So it can cover the bigger vessel because have 8 m deep‐water.

The facility is managed by logistic department of TEPI led by Mr. Fahril. There are also some representatives of various departments, like from drilling, fluid and cementing, warehouse, and asset management.

POSB base operates 24 hours x 7 a week. The main operation of this base is Handling and lifting (moving and placing all the drilling material), warehousing, LMP (OBM mud producer, and WBM raw material stocker), Vessel and Jetty, and tubular service (maintain the tubular from the corrosion, etc.)

I also utilized as the transit terminal for the service company’s equipment, because the whole marine operation (AHTS, transportation, tug supply) to or from the rig provided here. Now the base services 2 rig and going to be 5 rig this year. ‘

Totally, the base area in POSB reaches 22000 m2. 20000 m2 for pipiyard, 1500 m2 for transit area and 500 m2 is covered warehouse.

The LMP is operated by IM swaco and the cementing plant is operated by Halliburton. Beside send the mud and material, the base also provides the potable water for the offshore platform and rig. The mud from the rig also processed here (centrifuging) and the cutting send to BSS‐Pendingin before disposed.

The Cementing plant prepared the mixture of the cement based on the fluid engineer from TEPI. They have 3 main products, SSH ‐1, Microbon‐M (medium), and Microbon Addictive. The base material from the entire product is G


class cement provided by Indocement. To meet the product specification some chemical was added (like silica flour, sphere lite, etc.) using sandwich method. They have 2 mixing tanks to do the job.

CONCLUSION

After finishing the site visit program, the trainee can conclude several things, such as:

1. The trainee has a good knowledge about the whole business processes of TEPI, from the exploration, development, drilling, and production of the oil, gas and condensate.

2. WET trainee have a brief knowledge about the field operation, the relation and the organization of several department related to WCI, know the role of the well engineer, and the way other department support our job in the future.

3. Trainee learn and get several experience about Company cultures, have an inspirational experience, constructive criticism, and a lot of message to build the soft skill and about the engineer work from senior employee.

4. The Site Visit program is very useful for the new hired employee/trainee to have a good adaptation to their work atmosphere and environment


APPENDIX

[1] Slug‐Catcher

Slugcatcher is the name of a unit in the gas refinery or petroleum industry in which slugs at the outlet of pipelines are collected or caught. A slug is a large quantity of gas or liquid that exits the pipeline. It works using the influence of gravity. The liquids will tend to settle on the bottom of the pipeline, while the gases occupy the top section of the pipeline because have a weightier mass. Under certain operating conditions gas and liquid are not evenly distributed throughout the pipeline, but travel as large plugs with mostly liquids or mostly gases through the pipeline. These plug is called slug. Slugs can be generated by different mechanisms in a pipeline:

• Terrain slugging is caused by the elevations in the pipeline, which follows the ground elevation or the sea bed.

• Hydrodynamic slugging is caused by gas flowing at a fast rate over a slower flowing liquid phase. Riser‐based slugging, also known as severe slugging, is associated with the pipeline risers often found in offshore oil production facilities.

• Pigging slugs are caused by pigging operations in the pipeline. The slugcatcher is located between the outlet of the pipeline and the processing

equipment. The buffered liquids can be drained to the processing equipment at a much slower rate to prevent overloading the system. As slugs are a periodical phenomenon, the slugcatcher should be emptied before the next slug arrives.

[2] Separator

Separator is a pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components. A separator for petroleum production is a large vessel


designed to separate production fluids into their constituent components of oil, gas and water. A separating vessel may be referred to in the following ways: Oil and gas separator, Separator, Stage separator, Trap, Knockout vessel (Knockout drum, knockout trap, water knockout, or liquid knockout).

The proceses can be described like this, natural gas is lighter than liquid hydrocarbon. Minute particles of liquid hydrocarbon that are temporarily suspended in a stream of natural gas will, by density difference or force of gravity, settle out of the stream of gas if the velocity of the gas is sufficiently slow. The larger droplets of hydrocarbon will quickly settle out of the gas, but the smaller ones will take longer. At standard conditions of pressure and temperature, the droplets of liquid hydrocarbon may have a density 400 to 1,600 times that of natural gas

[3] Pigging

Pigging refers to the practice of using pipeline inspection gauges or 'pigs' to perform various maintenance operations on a pipeline. This is executed without stopping the flow of the product in the pipeline.

These operations includding cleaning operation and inspecting of the pipeline. This is accomplished by inserting the pig into a 'pig launcher' (or 'launching station') ‐ a funnel shaped Y section in the pipeline. The launcher / launching station is then closed and the pressure driven flow of the product in the pipeline is used to push it along down the pipe until it reaches the receiving trap ‐ the 'pig catcher' (or receiving station).


[4] DHSV ( Down Hole Safety Valve )

A downhole safety valve is a device placed inside the tubing, which acts as a valve to prevent the uncontrolled release of reservoir fluids from the bottom hole. It is almost always installed as a vital component on the completion.

In DHSV tube there are some valves. These valves are commonly uni‐directional flapper valves which open downwards, such that the flow of wellbore fluids try to push it shut, while pressure from surface pushes it open. This means that when closed, it will isolate the reservoir fluids from surface.

Most downhole safety valves are controlled hydraulically from surface, can be opened using a hydraulic connection linked to a well control panel. When hydraulic pressure is applied down a control line, the hydraulic pressure forces a sleeve within the valve to slide downwards. This movement compresses a large spring and pushes the flapper downwards to open the valve. When hydraulic pressure is removed, the spring pushes the sleeve back up and causes the flapper to shut. In this way, it will isolate the wellbore in the event of a loss of the wellhead

[5] Gas Lift

An artificial‐lift method in which gas is injected into the production tubing to reduce the hydrostatic pressure of the fluid column. The resulting reduction in bottomhole pressure allows the reservoir liquids to enter the wellbore at a higher flow rate. The injection gas is typically conveyed down the tubing‐casing annulus and enters the production string through a SMP (Side Pocket Mandrel). The SPM position, operating pressures and gas injection rate are determined by specific well conditions.


[6] TDU ( Thermal )

Thermal desorption is one of many methods used to clean up soil that has been contaminated with hazardous chemicals. By heating these soils to temperatures of 200‐1,000 degrees F, contaminants with low boiling points will vaporize or turn into gas and separate from the soil. These vaporized contaminants are then collected and treated. In this case, the soil is the cutting and the contaminant water and oil. Thermal desorption is a different process than incineration because it uses heat to physically separate the contaminants from the soil. They will then require further treatment. Incineration uses heat to destroy the contaminants.

The desorption unit is used to heat the contaminated soil to a high enough temperature for a long enough time to dry it and vaporize the contaminants from it. A common design for this unit is a rotary desorber, which has a rotating, cylindrical metal drum. In a direct‐ fired rotary desorber, the contaminated soil enters the rotating cylinder and is heated by direct contact with a flame or the hot gasses coming off a flame. In an indirect‐fired rotary desorber, the soil does not come into contact with a flame or combustion gases. Instead, the outside of the cylinder is heated and the hot metal indirectly heats the soil tumbling inside. As the soil is heated, the contaminants vaporize and become part of the gas stream of air and contaminated vapors flowing through the desorber toward the post‐treatment system.

The goal of any thermal desorption technology is to produce oil‐free or ultra‐low Total Petroleum Hydrocarbons (TPH) solids for disposal by distilling the oils from cuttings and recovering it to be reused as drilling fluid.


[7] Well Platform overview diagram

[8] Chirstmas Tree

A Christmas tree, is an assembly of valves, spools, and fittings used for an oil well, gas well, water injection well, etc.

It is installed on the casing head to seal the annular space between casing and tubing, control wellhead pressure, adjust well flow rate and transport oil to pipeline.through a flow line. This leads to a processing facility, storage depot and/or other pipeline eventually leading to a refinery or distribution center (for gas). The structure of the christmas tree can be shown below.


[9] CPA Proceses Diagram

Pump to Senipah


Date post:	26-Oct-2014
Category:	Documents
Upload:	sryn89
View:	124 times
Download:	3 times

FIELD Site Vist Report-WET 2012-I Gede Suryana S

Documents