Marcel Zeestraten, Phd Senior consultant – Concept Engineering

Upstream Oil & Gas

Conceptual Surface Facilities Design• Comprises the early stages of project development – Identify, Assess &

Select• Is an integral part of a Field Development Plan• Offers the best opportunity to influence the success of a project and

the value it creates• Requires low expenditure compared to the project execution stage• Requires a very small team of engineers, with a very broad skill set

Solid process engineering background Good understanding of other oil & gas disciplines

Reservoir engineering Production Technology Economics Production Chemistry Flow assurance Materials & Corrosion Project engineering Etc.

Creativity & ability to think out-of-the-box

Front End Loading• The practice of placing emphasis on the Conceptual Design phase in

Project Development

Conceptual Design of Surface Facilities

Marcel Zeestraten – Resume summary

Experience

Years

Upstream Oil and Gas industry 22Shell International Staff Pool 11

Scotland 2

England 1

Venezuela 4

Petroleum Development Oman 4

Other roles in Oman 11Petroleum Development Oman 4

BG group 3

Oman Oil E&P 1

Xodus (consultancy) 3

Feasibility / Select phases of project lifecycle 11

• PhD – Delft University of Technology, the Netherlands• Core discipline: Process Engineering

• Examples of Conceptual Designs delivered are given in the next few slides• Qualified HAZOP chairman

Conceptual Design Example 1: Abu Butabul – Oman Block 60 BG-Oman

Project Characteristics• Remote location (Oman Empty Quarter)• Gravel plain and high sand dunes• Tight gas / condensate field• Challenging because of marginal economics• High level of uncertainty regarding well productivity• Conceptual Surface Facilities design as Field Appraisal progresses• Design capacity 90 mmscf/d of gas and 6000 bbl/d of condensate

Many different concepts considered, depending on the scale of the development• Extended well testing facilities• Multiphase export to third party processing facilities• In-field processing plant to meet export specs

Significant conceptual design aspects • Accurate PVT characterization of well fluids• Multiphase flow• Corrosion and material selection• Multiphase pressure boosting• Gas dew point control (HC and water)• Condensate stabilization• Power generation• Water disposal (evaporation pond)• Third party contracts for processing and fluid transportation

Conceptual Design Example 2: Musandam Gas PlantOman Oil

Project Characteristics• High GOR sour oil• Offshore wellhead platform• Subsea multiphase production pipeline to shore• Export of stabilized crude to a tanker loading buoy• Gas conditioning and export to a nearby power plant• LPG extraction and export by road tanker• Sulphur recovery and export by road tanker• ‘Inherited’ process design required substantial rework.• Facilities cost approx. $600 million

Process Plant Elements• Slug catcher• HP three phase separator• Crude stabilization column• 2 stage gas compression• Gas sweetening (Amine process)• Sulphur recovery (Claus process)• Gas dehydration (TEG process)• Gas HC dew point control (low temperature

separation)• LPG extraction from gas condensate• Sour water stripper• Crude storage• Crude export to loading buoy• Road tanker loading for LPG and Sulphur• Flare• Utilities

Conceptual Design Example 3: Marmul Polymer projectPetroleum Development Oman

Off-plot facilities• Massive infill campaign doubles the number of wells from 600 to 1200 – with an

option to double again to 2400 wells in future• Surface congestion necessitates re-design of fluids gathering system• Innovative design realizes $200 million savings in fluid gathering• A further $100 million savings identified subject to a successful technology trial• Design allows switch over from old to new design with minimal deferment

On-plot facilities• Water de-oiling in the presence of back-produced

polymer challenges existing technology Search for innovative technologies in the market

that meet that challenge• Substantial expansion of produced water clean-up,

pumping and polymer mixing facilities.

Total surface facilities cost exceeds $ 1 billion.

Conceptual Design Example 4: Field Development PlansPetroleum Development Oman

Project Characteristics• FDP studies for 3 clusters totaling 15 fields have been awarded to consultant• Predominantly brown field developments• Two clusters have been completed so far.• Surface facilities conceptual designs identify > $100 mln in savings

Subjects Addressed• Evaluate opportunities to recover flared gas

economically• Trouble shoot operational problems related to control

of deep water disposal pumps with variable speed drive

• Identify causes of poor well test accuracy• Evaluate pros and cons of produced water re-injection

vs. injection of water from water supply wells• Design well testing and produced fluids gathering

systems to minimize cost.• Identify surface facilities debottlenecking

requirements to accommodate incremental production and water injection rates.

HAZOP Chairman

Approved HAZOP Chairman for Petroleum Development Oman

Examples of HAZOP studies chaired recently:• 11 km Gas Pipeline in Kurdistan

Client: DNO• High GOR, 10% H2S early production facility in Kurdistan

Client: HKN