Process Related, Mechanical and Piping Workshop by Technip

PROGRAM OF THE DAY:
1) Introduction of TECHNIP (and myself)
2) Process related aspects in offshore
oil and gas
3) Specific lay-out aspects of offshore
platforms (piping / mechanical)
Lecture for Avans 2015, Baijan Savalan – Process technologist

Herman Hamhuis
 8 jaar werkzaam in Engineering
 Ervaring in Olie/Gas, Petrochemie, en Chemie
 Werkzaam bij TECHNIP-EPG
 Huidige functie: Lead process engineer (hiervoor Tebodin, Zeton)
 Bijzonderheden: Ook werkzaam geweest als project engineer en site
engineer

Technip Today
With engineering, technologies and project management, on land and at sea, we safely and
successfully deliver the best solutions for our clients in the energy business
Worldwide presence with 36,500 people in 48 countries
Industrial assets on all continents, a fleet of 34 vessels (of which 5 under construction)
2013 revenue: €9 billion (€15 billion backlog)
Energy is at the core of Technip
Technip Presentation4

Engineering and fabrication of fixed
platforms for shallow waters (TPG
500, Unideck®)
Engineering and fabrication of
floating platforms for deep waters
(Spar, semi-submersible
platforms, FPSO)
Leadership in floatover technology
Floating Liquefied Natural Gas
(FLNG)
Construction yard
Design, manufacture and supply of
deepwater flexible and rigid
pipelines, umbilicals and riser
systems
Subsea construction, pipeline
installation services and Heavy Lift
Six state-of-the-art flexible pipe and /
or umbilical manufacturing plants
Five spoolbases for reeled pipeline
assembly as well as four logistic
bases
A constantly evolving fleet
strategically deployed in the world's
major offshore markets
Three Business Segments, One Technip
Gas treatment and liquefaction
(LNG), Gas-to-Liquids (GTL)
Oil refining (refining, hydrogen and
sulphur units)
Onshore pipelines
Petrochemicals (ethylene,
aromatics, olefins, polymers,
fertilizers)
Process technologies (proprietary or
through alliances)
Biofuel and renewable energies
(including offshore wind)
Non-oil activities (principally in life
sciences, metals & mining,
construction)
Subsea Offshore Onshore
The best solutions across the value chain

A Unique Worldwide Footprint

Subsea:
Worldwide Leading Integrated Player
Products
Flexible pipe
(in house manufacturing)
Umbilicals
(in-house manufacturing)
Rigid pipelines
Services
Inspection,
repair & maintenance
Flexible/rigid pipelaying
(Reel, S-Lay & J-Lay)
Heavy Lift Operations
Deep water installation
& construction
Vertical integration
In-house technologies
Worldwide leadership
First class assets
Architecture

Technip Slide Library8
Offshore:
Expertise in High Added-value Technology
WindFPSO/FLNGSparSemi-submersibleUnideck®TPG 500 TLP
Innovative capabilities
Heavy lift capabilities
Proprietary platform design
Proven track record in engineering & construction

Technip Onshore Segment
 Refining & heavy oil
 Clean fuels
 Grassroots
 Heavy oil upgraders
 Hydrogen
Gas Processing
Gas treatment
GTL
LNG
Petrochemicals
Ethylene
Polyolefins
Aromatics
Fertilizers
Project management consultancy
Strong process engineering capabilities
Process technologies (Hydrogen, Ethylene, Refining, Petrochemical & GTL)
Solid reputation with NOCs & IOCs
Others
Mining and metals
Infrastructures
Buildings
Life sciences,…

Floating LNG Solutions
A unique combination of technologies and know-how
from our 3 business segments
Cryogenic pipe-in-pipe
Processing systemCryogenic flexible pipe FPSOSubsea services
& product provider

Technip in the Benelux
1111 Technip Presentation

Technip in the Benelux
12
Rotterda
Bergen op
Zoom
's
Rotterdam
Bergen op
Zoom
's Hertogenbosch
Zoetermeer
Technip Benelux B.V.
Technip-EPG B.V.
• Turnover, MM Euro : 160-170
• Employees : 600
• Project hrs / yr : 650,000+
Zoetermeer
Capelle a/d IJssel
Antwerpen
Bergen op Zoom ‘s-Hertogenbosch
Technip Benelux N.V.
Antwerpen

Technip Manpower in the Benelux
0
20
40
60
80
100
120
140
160
Process
Mechanical
E&I
Civil&…
HVAC
Execution
Constructio…
Procurement
Finance&…
Others
Staff
Discipline
Staff Technip Benelux
TP Antwerp
TP EPG
TP Zoetermeer

Technip Benelux - NL Headquarters
14
 Full EPC capabilities
 From pre-feasibility up to start-up
 Project Management
 Strong front-end engineering capabilities
and advisory services
 Procurement, Expediting, QA/QC
 Construction, Commissioning, Start-up
 Technology center for Ethylene,
Hydrogen and Syngas

Technip Netherlands Presentation15
Technip Benelux B.V. – Main Product Lines
15
Over 550 ethylene furnaces built
Petrokemya, Saudi Arabia

Technip-EPG
16

Engineering Services
 Studies and Consultancy
 Engineering
 Basic Engineering
 Detail Engineering
 Scope definition and (cost) estimating
 Procurement
 Purchasing
 Inspection
 Expediting
 Construction
 Construction management

Engineering Services
 Engineering Procurement Construction (EPC)
 Revamp and Grass Root
 100 – 100.000 hours
 Contracts
 Lump Sum Turnkey
 Reimbursable
 Incentive
 High Value Technip centers

Process + HSE
 Process Study
 Flow Assurance
 Process Flow Diagrams PFD’s
 Piping Instrumentation Diagrams P&ID’s
 Equipment-specification
 Hazard & Operability studies (HAZOP)
 Validation processes

Electrical & Instrumentation
 High, mid and low voltage
 ATEX 95/137
 DCS/PLC-configuration
 Instrumentation
 Fieldbus; Foundation Fieldbus, Profibus
 Load-flow and motorstart calculations
 Short-circuit calculations
 NEN 3140-Inspection
 NEN 1010-Inspection
 SIL - Classification

Mechanical / piping
 3D-Design, new installation and modifications
 Plot study
 Pipe stress calculations
 Pipe specification-calculations
 Pressure vessel calculations
 PED-classification

G17d-AP
Technip-EPG
 Segment : Oil & Gas Offshore
 Client : GDF Suez E&P Nederland B.V.
 Project : G17d-AP Compression
 Scope : Integration of the Low Low
compression facilities
 Platform & Compressor modifications
 Hang-of module 10 x 7 x12,5 mtr
 Lifting weight 200 ton.
 Disciplines :
 Project management, Process, Piping and
Structural, Instrumentation and Electrical
 Execution: 2011 - present Technip is qualified to perform the works
with the highest HSSE standards

Technip Presentation23 Technip Presentation23
K2b-A
Technip-EPG
 Segment : Offshore
 Client : Gaz de France
 Project : K2bA Compression
 Detail engineering for compressor unit, to be
installed on existing platform
 Disciplines
 Project management
 Piping
 Pipestress
 Structural
 Execution: 2007-2008, 9.000 hrs
Vibration study & analysis
and coördination with TNO
were subject to this project

K5-A /K4-Z
Technip-EPG
 Client : Total E&P Nederland
 Project : K4-Z / Topside modifications K5-A
 Scope : Engineering & Procurement
 New equipment/facilities to be installed
 Water Treatment unit, Oil Absorption filters, Methanol and
KHI/CI Injection skids, Separator modifications, E&I room,
HPU, Fire walls.
 ESD valves, Choke valve and Electrical Heater are
installed in a new Hang off Module.
 Additional Weight
 Steel 50 Ton, Equipment 50 Ton (dry weight)
Piping and supports 25 Ton (dry weight)
 Disciplines
 Project management, HSE, Process, Mechanical, Piping &
Pipe Stress, Structural, Electrical & Instrumentation,
Procurement, Expediting and QA/QC.
 Execution: 2011/2012, 20.000 hrs

K4-BE
Technip-EPG
 Client : Total E&P Nederland
 Project : K4-BE
 Scope : Engineering & procurement services
 New equipment to be installed
 Skimmer tank (3 phase separation)
 Disciplines
 Project management, Process, Piping, Mechanical,
 Structural, Instrumentation, Electrical,
 Procurement services (Expediting QA/QC)
 Execution: 2011, 2000 hrs

Our knowledge and experience contribute
to the success of our clients
Why Technip is an excellent choice
 Broad experience in the industry
 Flexible set-up of project team
 State-of-the-Art tools
 Located close to the client, therefore able to
immediately respond to requests
 Committed to a code of business ethics
 Full access to resources and technologies
of TECHNIP GROUP, ranking top 5 major
players in engineering and construction
services worldwide

Process related aspects in
offshore oil and gas

Technip EPG28
Table of contents
1. General
2. Process Flow Diagram (In satellite and central processing platforms)
3. Gas / Liquid separation
4. Water / Condensate Separation
5. Chemical Injection
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG29
Table of contents
1. General
2. Process Flow Diagram(In satellite and central processing platforms)
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

30 Technip EPG
Gas
Condensate
Water
Water
Sea water
1. General
Gas Reservoir

31 Technip EPG
1. General
Exploration
 Seismic survey

32 Technip EPG
1. General
“Nederlands plat”
•Government sells clusters to O&G operators

33 Technip EPG
1. General
“Nederlands plat”

Het Nederlands plat
Gaz de France
Nederlandse
Aardolie
Maatschappij
Wintershall
Clyde
Nu Wintershall
Bloknummer
GasveldOlieveld

1. General
Gas Field Layout
Satellites
Central
Processing

 Well fluid gathering manifold
 Bulk water separation
 Chemical injection
 Pig launcher
...
1. General
Satellite Platform

1. General
Satellite Platform
Bulk Separation
Pumping/Metering
Sea Water
Produced Water
Diesel Power Gen
Gas Metering
Wellheads
Overboard
Crude Export
Gas Export
Crane
Diesel
Chemical Injection
Flare/Vent
Closed, Haz Drains
Pig Launcher

 Gathering manifold of all the
connected satellites
Fine tuned water separation
 Dehydration
 Compresssion
 Chemical injection
 Pig launcher / Receiever
...
1. General
Central Processing Platform

1. General
Instrument Air
Bulk Separation
Pumping/MeteringFinal Separation
Flash Gas
Compression
Export Compression
Cooling Medium Sea Water
Water Injection
Produced Water
Fire Water
DCS
Gas Turbine Power Gen
Fuel Gas
Gas Metering
Satellites
Dehydration
Overboard
Crude Export
Gas Export
AccommodationDiesel
Chemical Injection
Flare/Vent Non-Haz Drains
Closed, Haz Drains
Potable Water
Pig Launcher / Receiver
Wellheads

Technip EPG40
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

MeOH or
MEG Injection
Gas/Liq
Separator
Wat / Cond.
Separator
2. Process Flow Diagram
Satellite Platform
Degassing
Drum
Gas + Cond. To
Central Processing
Platform
Water Overboard
MEG-CI Injection
Skimmer

Gas/Liq
LP
Separator
2. Process Flow Diagram
Degassing
Drum
Water Overboard
HP LP
KO
Drum
Gas/Liq
HP
Separator
Metering
Export Gas
To Pipeline
DEG
Skimmer
Degassing
Drum
Cond. Storage
drum

Technip EPG43
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG44
 Removal of water and condensate from gas
3. Gas/Liq. Separation
 Purpose

Two-Phase Separator
Gas / Liq. Inlet
Gas Outlet
Liq. (Cond. + Water) Outlet

Two-Phase Separator

Technip EPG48
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG49
 Separate water from condensate
 Separate remaining condensate from water to make the water
ready for overboard conditions
 Purpose
4. Water /Condensate Separation

MeOH or
MEG Injection
Gas/Liq
Separator
Wat / Cond.
Separator
4. Water /Condensate Separation
Degassing
Drum
Gas + Cond. To
Central Processing
Platform
Water Overboard
MEG-CI Injection
Skimmer

51 Technip EPG
4. Water/Condensate Separation

MeOH or
MEG Injection
Gas/Liq
Separator
Wat / Cond.
Separator
Degassing
Drum
Gas + Cond. To
Central Processing
Platform
Water Overboard
MEG-CI Injection
Skimmer

53 Technip EPG

Technip EPG54
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG55
 Prevent piping and pipeline from rupture
 Prevent hydrate/wax formation and blocking of piping / pipeline
 Purpose

56 Technip EPG
 Hydrate (Ice that burns)
Crystalline compounds of water and light hydrocarbon molecules
 Ice-like solid crystals
 Cages of water molecules surrounding hydrocarbon molecules
 Can form in gas, gas-condensate and black oil systems
 Forms at temperatures higher than 32ºF (up to 80°F) at high pressure
 Transient operations are very susceptible to hydrate blockages
 Blockages can occur very rapidly
Hydrate Inhibitor (MeoH / MEG)

57 Technip EPG
Corrosion Inhibitor (CI)
Pipeline corrosion can be inhibited
by several means.
Choice of corrosion-resistant
metals, alloys
Injection of corrosion inhibitors
Cathodic protection
External and/or internal
protective coatings

58 Technip EPG
Wax Inhibitor

Technip EPG59
 Prevention of killing the well in order to explore the “latest” gas
 Purpose
Foam injection

Technip EPG60
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG61
 Boost the gas to the conditions (higher pressure) of delivery
for export gas
6. Compression
 Purpose

Gas/Liq
LP
Separator
6. Compression
Degassing
Drum
Water Overboard
HP LP
KO
Drum
Gas/Liq
HP
Separator
Metering
Export Gas
To Pipeline
DEG
Skimmer
Degassing
Drum
Cond. Storage
drum

63 Technip EPG
6. Compression
Centrifugal Compressor

64 Technip EPG
6. Compression
Axial Compressor

65 Technip EPG
6. Compression
Rotary Compressor

66 Technip EPG
6. Compression
Recip. Compressor

Technip EPG67
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG68
 Dry gas to avoid gas hydrate formation as well as to reduce
corrosion
 Meet delivery specifications (dew point e.g -8°C @ 72 barg)
7. Dehydration
 Purpose

Gas/Liq
LP
Separator
7. Dehydration
Degassing
Drum
Water Overboard
HP LP
KO
Drum
Gas/Liq
HP
Separator
Metering
Export Gas
To Pipeline
DEG
Skimmer
Degassing
Drum
Cond. Storage
drum

70 Technip EPG
7. Dehydration
Wet Gas
Rich
Glycol
DryGas

Technip EPG73
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

74
8. Export Pipeline
Technip EPG

75
8. Export Pipeline
Technip EPG

Technip EPG76
Table of contents
1. General
6. Compression
7. Dehydration
8. Export Pipeline
9. Pigging

Technip EPG77
 Check wall thickness and find damaged sections of lines
(intelligent pigging / imposed by SODM)
 Remove debris such as dirt and wax from lines
 Provide a known volume for calibrating flow meters
 Coat inner pipe walls with inhibitors
 Remove condensed hydrocarbon liquids and water in two phase
pipelines
9. Pigging
 Purpose

79
9. Pigging
Large amounts of liquid can collect in front of the pig
Technip EPG

3) Specific lay-out aspects of
offshore platforms (piping /
mechanical)

De bovenbouw ”TOPSIDE”
De configuratie wordt bepaald door:
Samenstelling van het gas.
• De productiecapaciteit
• Permanente of tijdelijke boortoren
• Accommodatiefaciliteit
• Helikopterdek
• Opslagcapaciteit
• Brugverbindingen met andere platforms
• Hijskraanfaciliteit
• Utiliteitsystemen

Onderbouw ”JACKET”
Afhankelijk van de waterdiepte worden verschillende jackets toegepast
TOPSIDE
JACKET
0
50
150
100
200

Jackets zijn globaal te verdelen in
• Een stalen buizen frame
• Betonnen structuren
•Tension Leg Platform

Een stalen buizen frame.

Een stalen buizen frame

Een stalen buizen frame.
Het frame wordt met heipalen in de zeebodem bevestigd.
JACKET
Heiblok
Heipaal
geleider

Betonnen structuren
Onderbouw “jacket”

Tension Leg Platform
Onderbouw “jacket”

Installatie van een platform op de Noordzee
Het platform en de jacket worden met een kraanschip
naar de lokatie gebracht.
Platform

Jacket wordt vast geheid in de zee bodem.
JACKET
Heiblok

De topside wordt op het jacket geplaatst
Topside
JACKET

De topside wordt op het jacket geplaatst
JACKET
Topside

Het platform wordt door een transportleiding met het hoofdplatform verbonden.
Pijpenlegger
Aanvoer transportleiding

De Solitaire 1

Bevoorrading pijpenlegger op zee

Lassen van de transportleiding op de pijpenlegger

Voorbereiding voor aansluiten transport leiding op hoofdeiland

Als laatste wordt de definitieve put geboord

De FPSO
 Voor olie en gaswinning op grote diepte en kleine velden worden FPSO’s
toegepast.
 FPSO is Floating Production Storage and Offloading vessel
 Boven het scheepsdek worden alle productie faciliteiten voor de olie en gas
behandeling geplaatst.
 De productie unit is modulair opgebouwd.

Equipment layout
Een offshore platform is uit de volgende dekken opgebouwd
 helicopter deck (heli deck)
 main deck (upper deck)
 intermediate deck (mezzanine deck)
 cellar deck
 sub-cellar deck

Equipment layout
Heli deck
Main deck
Cellar deck
Sub Cellar
deck
intermediate
deck

Equipment layout
Helicopterdeck (heli deck)
 Bevindt zich boven het living quarter.
 Vrij van obstakels
 Afmetingen worden bepaald door het type helicopter wat in het veld
gebruikt wordt.

Equipment layout
Helicopterdeck (heli deck)

Equipment layout
main deck (upper deck)
 Utility equipment
 Generatoren
 Gascompressoren
 Koelerbanken
 Hijskraan
 Toegangsluiken voor onderhoud
 Toegangsluiken van de putten
 Container opslag
 Wire line unit

Equipment layout
Wire line unit

Equipment layout
main deck (upper deck)

Equipment layout
intermediate deck (mezzanine deck)
 instrumentation/ switchgear/ battery and transformer room
 Instrument air vessel
 Methanol injection pumps

Equipment layout
Intermediate deck (Mezzanine deck)

Equipment layout
Cellar deck
Hazardous area
 Wellheads
 Separatoren
 Test & production manifold
 Vent knock-out drum
 Condensate injection pumps
 Methanol injection pumps
 Inhibitor injection pumps

Equipment layout
Cellar deck
Non hazardous area
 Deluge skid
 Koelwater pompen
 Brandbestrijdingspompen
 Personeelsaccomodatie (living quarter)
 Evacuatieplaatsen

Equipment layout
Sub-cellar deck
 noodafsluiters (emergency shut down valves)
in de in en uitgaande export leidingen.
 de pig launchers/ receivers.
 de closed en open drain tanks inclusief pompen.
 skimmer tank.

Equipment layout
Sub-Celllar deck

Platform oriëntatie
Bepaald door
 Stromingsrichting van het zeewater
 Meest voorkomende windrichting (prevailing wind)
 Plaats van de risers die langs het jacket naar de zeebodem lopen
 De plaats van de aanlanding (boat-landing) voor bevoorrading

Bepaald door

Bepaald door
 Toekomstige putboringen
 De helicopter moet in alle windrichtingen kunnen landen en opstijgen.
 Plaats van de fakkel en vent leidingen.
 De hoogte van het sub-cellar deck wordt bepaald door de 100 jarige golf
plus de air gap van 1 meter.

Platform elevatie
Bepaald door
 De hoogte van het sub-cellar deck wordt bepaald door de 100 jarige golf
plus de air gap van 1 meter.

Design criteria voor equipment location plan
 Equipment op een logische plaats
 Economische equipment opstelling
 Veiligheidsvoorschriften raadplegen
 Toegankelijkheid voor het plegen van onderhoud en bedienbaarheid

Design criteria voor equipment location plan
 Voldoende onderlinge ruimte
 Hazardous en non-hazardous.
 Fire-wall (brandbescherming) of een blast-wall.
 Vluchtwegen aangeven 1200 mm breed 2300mm hoog
 Onderhoud en inspectie 800 mm breed
 Lay-down area aangeven

Escape routes/fire-fighting layouts
 Vluchtwegen naar de evacuatie plaatsen
 Reddingsboten (escape capsules of free fall boats)
 Locatie van brandblusmiddelen

Process Related, Mechanical and Piping Workshop by Technip

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