Offshore Operations and Engineering

307 Pages·2019·26.618 MB·English

by  Shashi Shekhar Prasad Singh, Jatin Agarwal, Nag Mani

Offshore Operations and
Engineering

Offshore Operations and
Engineering
Shashi Shekhar Prasad Singh,
Jatin  R.  Agarwal, and Nag Mani
CRC Press
Taylor & Francis Group
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Contents
Foreword ................................................................................................................xvii
Preface.....................................................................................................................xix
Acknowledgments ...................................................................................................xxi
Authors .................................................................................................................xxiii
Chapter 1 Introduction to Offshore Operation ......................................................1
1.1 Ocean Baseline ..........................................................................1
1.2 Ocean Environment ...................................................................2
1.2.1 Metocean Condition and Study ....................................2
1.2.2 Meteorology .................................................................3
1.2.3 Physical Oceanography ................................................3
1.2.4 Metocean Data .............................................................4
1.3 Offshore Oil and Gas Production ..............................................4
1.3.1 Comparison of Onshore versus
Offshore Oil Production ...............................................5
1.3.2 Comparision of Offshore Oil Production on the
Basis of Water Depth ....................................................6
1.3.3 Rig Count and Utilization Rate ....................................7
1.4 Offshore Operations ..................................................................7
1.4.1 Notable Offshore Fields across the Globe ..................10
1.4.2 Major Offshore Oil Producing Countries ...................10
1.4.3 Offshore Facilities (Installations/Platforms/Rigs) .....11
1.4.4 Types of Offshore Installations/Platforms .................11
1.4.5 Type of Offshore Rigs ................................................11
1.4.6 Challenges with Offshore Facilities ...........................11
1.4.7 Ecological and Environmental Risks .........................12
1.5 How Are Offshore Operations Different from Onshore .........13
1.5.1 Safety Requirements ..................................................13
1.6 Technology Wave.....................................................................13
References ..........................................................................................14
Chapter 2 Offshore Structure and Design ...........................................................15
2.1 Structural Designing ...............................................................16
2.1.1 Corrosion Protection ..................................................17
2.1.2 Cathodic Protection ....................................................17
2.1.2.1 Impressed Current Cathodic
Protection Systems......................................18
2.1.2.2 Sacrificial Anodes (Galvanic Action) .........18
2.1.3 Loads ..........................................................................19
2.1.3.1 Constant Loads ...........................................19
v
vi Contents
2.1.3.2 Variable Loads ............................................19
2.1.3.3 Environment-Dependent Loads
(Normally Calculated on Historically
100-Year Return Period) .............................20
2.1.3.4 Additional Loads during Installation
and Construction .........................................22
2.1.3.5 Unforeseen Load .........................................22
2.2 Fixed Platforms .......................................................................22
2.2.1 Concrete Gravity Structure ........................................22
2.2.1.1 Design .........................................................25
2.2.1.2 Construction and Installation .....................26
2.2.2 Compliant Tower and Guyed Tower ...........................27
2.2.2.1 Design .........................................................27
2.2.2.2 Construction and Installation .....................28
2.2.3 Jacketed Platform .......................................................30
2.2.4 Jackup Platform/Rig ...................................................33
2.2.4.1 Design .........................................................33
2.2.4.2 Installation ..................................................34
2.3 Floating Platform .....................................................................35
2.3.1 Mooring and Anchoring .............................................35
2.3.1.1 Classification of Mooring Systems .............38
2.3.1.2 Catenaries Mooring System .......................38
2.3.1.3 Single Point Mooring System .....................39
References ..........................................................................................40
Chapter 3 Offshore Drilling and Completion .....................................................43
3.1 Offshore Drilling .....................................................................43
3.1.1 Introduction ................................................................43
3.1.2 Well Planning .............................................................44
3.1.2.1 Geology .......................................................45
3.1.2.2 Completion Design .....................................45
3.1.2.3 Trajectory Design .......................................45
3.1.2.4 Wellbore Stability .......................................46
3.1.2.5 Drilling Fluid Design..................................46
3.1.2.6 Casing Design .............................................46
3.1.2.7 Cement Job Designs ....................................46
3.1.2.8 Wellhead/Blowout Prevention (BOP)
Design .........................................................46
3.1.2.9 BHA and Drill String .................................46
3.1.2.10 Bit Design ...................................................46
3.1.2.11 Hole Cleaning and Hydraulics ....................46
3.1.2.12 Rig Equipment ............................................46
3.1.3 Rig Selection Criteria .................................................47
3.1.3.1 HSE Compatibility ......................................47
3.1.3.2 Technical Capability ...................................47
Contents vii
3.1.3.3 Full-Cycle Efficiency ..................................47
3.1.4 Wellbore Stability .......................................................47
3.1.4.1 Stress Distribution around the Wellbore .....48
3.1.4.2 Establishing a Minimum Safe
Mud Weight ...............................................49
3.1.4.3 Validating the Geomechanical Model .........50
3.1.4.4 Sand Production ..........................................51
3.1.5 Casing Design ............................................................51
3.1.5.1 Casing Program ..........................................51
3.1.5.2 Loads Encountered While
Designing Casing ........................................52
3.1.6 Trajectory Design .......................................................57
3.1.6.1 The Target ...................................................58
3.1.6.2 Kick-Off Point and Build-Up Rate .............58
3.1.6.3 Tangent Section ...........................................59
3.1.6.4 Drop-Off Section ........................................59
3.1.6.5 Trajectory Measurements ...........................59
3.1.7 Directional Drilling ....................................................64
3.1.7.1 Evolution of Directional Drilling ...............64
3.1.7.2 Types of Directional Wells .........................64
3.1.7.3 Conventional Drilling versus
Directional Drilling ....................................65
3.1.7.4 Directional Drilling Tools ..........................65
3.1.7.5 Measurement While Drilling
(MWD) Tool ..............................................65
3.1.7.6 Importance and Uses of Directional
Drilling .......................................................66
3.1.7.7 Application of Directional Drilling ............67
3.1.8 Dual Gradient Drilling ...............................................68
3.1.8.1 Introduction ................................................68
3.1.8.2 Dual Gradient Drilling – Overview ............68
3.1.8.3 Single versus Dual Gradient Drilling .........68
3.1.8.4 Dual Gradient System .................................69
3.1.8.5 Types of Dual Gradient Drilling.................70
3.1.8.6 Limitations of DGD ....................................71
3.2 Offshore Well Completion .......................................................72
3.2.1 Introduction ................................................................72
3.2.2 Well Completion Concepts in Offshore .....................73
3.2.2.1 Classification of Completions .....................73
3.2.3 Horizontal Well Completions .....................................80
3.2.3.1 Open Hole Completion ...............................80
3.2.3.2 Slotted Liner Completion............................80
3.2.3.3 Slotted Liner Completion for
Zonal Isolation ............................................81
3.2.3.4 Cemented and Perforated Completion ........82
3.2.4 Intelligent Well Systems .............................................83
viii Contents
3.2.5 Multilateral Completions ............................................83
3.2.5.1 Multilateral Well Classification ..................84
3.2.5.2 Level 1 Multilateral Well ............................84
3.2.5.3 Level 2 Multilateral Well ............................85
3.2.5.4 Level 3 Well Completions ...........................86
3.2.5.5 Level 4 Well Completions ...........................86
3.2.5.6 Level 5 Well Completions ...........................86
3.2.5.7 Level 6 Well Completions ...........................86
3.2.6 Subsea Completion .....................................................86
3.2.6.1 Types of Subsea Completions .....................87
3.2.7 Completion Equipment ...............................................89
3.2.7.1 Christmas Tree (Xmas Tree) ......................89
3.2.7.2 Production Tubing .......................................89
3.2.7.3 Packers ........................................................90
3.2.7.4 Blast Joint ....................................................92
3.2.7.5 Flow Coupling ............................................92
3.2.7.6 Seating Nipple .............................................92
3.2.7.7 Landing Nipple ...........................................93
3.2.7.8 Expansion Joint ...........................................93
3.2.7.9 Safety Joints ................................................93
3.2.7.10 Safety Valves ..............................................93
3.2.7.11 Circulating Valves.......................................95
References ..........................................................................................96
Chapter 4 Offshore Oil and Gas Production and Transportation .......................99
4.1 Offshore Production Operation ...............................................99
4.1.1 Major Elements of Offshore Production System ......100
4.1.1.1 Wells (Subsea/Platform Wells) .................100
4.1.1.2 Platform Wells/Dry Trees .........................100
4.1.1.3 Subsea Wells/Wet Trees ...........................100
4.1.1.4 Offshore Pipelines ....................................101
4.1.1.5 Processing Platforms ................................101
4.1.1.6 Export Pipelines/Tankers for
Evacuation of Oil and Gas ........................102
4.1.2 Maintenance and Supply ..........................................103
4.1.3 Essential Personnel/Workforce ................................103
4.1.4 Risks .........................................................................105
4.1.4.1 Basic Protection Concepts ........................105
4.1.5 Prevention .................................................................105
4.1.6 Shut In ......................................................................107
4.1.6.1 Fire and Gas Leakage
Protection System..................................107
4.1.6.2 Technology Development: HIPS ..............107
4.1.6.3 Surface Facility Protection .......................107
4.1.6.4 Well Control and Protection .....................109
Contents ix
4.1.7 SCADA – An Essential Part of Digital
Oil and Gas Field ......................................................109
4.1.7.1 Process Levels in SCADA ........................109
4.1.7.2 Instrumentation, Remote Sensing, and
Telemetry of Real-Time Processes ...........111
4.1.8 Automated Gas Lift Optimization in Offshore ........114
4.2 Processing in Offshore ..........................................................116
4.2.1 Oil Treatment ...........................................................116
4.2.1.1 Important Notes ........................................118
4.2.1.2 Loading of Tankers ...................................118
4.2.2 Gas Treatment ..........................................................118
4.2.2.1 Gas Dehydration Follows the Steps Below ...119
4.2.3 Produced Water Treatment .......................................120
4.3 Sea Water Injection ................................................................121
4.4 Offshore Storage ....................................................................122
4.5 Transportation of Oil and Gas ...............................................123
4.5.1 Oil Tankers ...............................................................123
4.5.2 Pipelines ...................................................................124
4.5.3 Floating Production, Storage, and
Offloading (FPSO) ...................................................124
4.5.3.1 Single Buoy Mooring ................................125
References ........................................................................................126
Chapter 5 Utilities and Support System ............................................................127
5.1 Living Accommodation .........................................................127
5.1.1 Medical .....................................................................128
5.1.2 Smoking and Alcohol ...............................................129
5.1.3 Entertainment and Recreation ..................................129
5.2 Power Generation ..................................................................129
5.2.1 Fuel Gas System .......................................................129
5.2.2 Utility/Diesel Generators .........................................130
5.2.3 Gas Turbine Generator .............................................130
5.3 Instrument and Utility Air System ........................................132
5.3.1 Air Compressors .......................................................132
5.3.2 Instrument Air and Utility Air Systems ...................132
5.4 Hot Oil System ......................................................................133
5.4.1 Crude Oil Heater ......................................................133
5.4.2 Chemical Tank .........................................................133
5.4.3 Glycol Reboiler .........................................................133
5.4.4 Skimmer Vessel ........................................................133
5.5 Potable Water System ............................................................133
5.6 Water Cooling System ...........................................................134
5.6.1 Freshwater Cooling System ......................................134
5.7 Utility Water System .............................................................135
5.8 Drain Header and Sump Caisson ..........................................135