modular equipment

7/28/2019 modular equipment

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Expros Modular Equipment Package

exprogroup.com

The modular equipment package is a three-phase separation train, complete with electrostatic

coalescer for crude oil dehydration to export specification.

This package has proved to be extremely flexible, operating on a range of applications from offshore extended well tests (EWT) to onshore

early production facilities (EPF) providing our customers with valuable reservoir data and/or early cash flow to assist with development of

their life-of-field solutions.

This equipment can be made available at short notice either on a where-is, as-is basis or, supplemented with additional equipment to meet

your project specific needs.

The modular equipment package was initially used in 2001 offshore the Philippines for the Shell Malampaya EWT. The EWT was carried out

on the Atwood Falcon Semi Submersible Drilling rig and flowed a total of almost two million barrels during the planned 150 day operation.

Following the successful Malampaya EWT the flexibility of the modular equipment package was highlighted when in 2002 it was redeployed

for a period of nine months onshore Indonesia for Kufpecs EPF on the Oseil Field. The package was subsequently redeployed on the same

location for Kufpec in 2005 for a period of 3 months while essential maintenance work was carried out on Kupecs permanent facility.

The modular equipment package was reconfigured in 2006 to meet the demanding process requirements (heavy oil) for the Shell EWT on

the BS-4 Field offshore Brazil, further testimony to the systems operating flexibility. The EWT was carried out from the drill-ship Deepwater

Navigator.

At the end of 2008 the modular equipment package was completely refurbished to an as new condition and is currently

available for redeployment to meet our customers' needs as required.


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Design Specification

Design codes & standards

exprogroup.com

The process package is designed and built to the following international design codes & standards:

The actual throughput that can be achieved with this package is dependent on the nature of the well fluids being processed and the inlet

conditions experienced at the inlet manifold. However, the following information is intended as a guide to the overall processing capabilities

of the package Expro Production Systems would be pleased to evaluate the throughput of these facilities upon the receipt of project specific

design conditions:

Potential Throughputs:

Maximum Fluid Flow Rate 32,000 bfpd

Maximum Oil Flow rate 25,000 bopd

Maximum Water Flow Rate 7,500 bwpd

Maximum Gas Flow Rate 45 MMscfd

Inlet conditions:

Maximum wellhead shut-in pressure 5,000 psig

Maximum wellhead flowing pressure 1,440 psig

Wellhead F lowing Temperature 122 to 176 F

Oil Gravity 13 to 43 API

Export parameters:

Maximum export pressure 245 psig

Typical export oil BS&W 0.5 %

Stabilised crude oil Reid Vapour 11 psia

Pressure (RVP)

Society

American Society of

Mechanical Engineers

American Petroleum

Institute

Description

Chemical Plant & Petroleum Piping Systems.

Boiler & Pressure Vessel Code.

Boiler & Pressure Vessel Code.

Analysis, Design, Installation & Testing Of Basic Surface Safety Systems For Offshore Production Facilities.

Recommended Practice For Design & Installation Of Offshore Production Platform Piping Systems.

Recommended Practice For Classification Of Locations For Electrical Installations At Petroleum Facilities

Classed As Class I, Division 1 & Division 2

Recommended Practice For Classification Of Locations For Electrical Installations At Petroleum Facilities

Classed As Class I, Zone 0, Zone 1 & Zone 2

Sizing, Selection, & Installation Of Pressure Relieving Devices In Refineries.

Guide For Pressure Relieving & De-Pressuring Systems.

Installation Of Refinery Instruments & Control Systems

Reference

ASME/ANSI B31.3

ASME VIII DIV. I

ASME VIII DIV. II

API 14C

API RP 14E

API RP 500

API RP 505

API 520

API 521

API 550

Basic Process Flow Diagram


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Equipment List

exprogroup.com

The basic package consists of the following main equipment items:

Inlet desander - Optional for use during initial well clean-up

Choke manifold skid - 31/8, 5k psig

Inlet pre-heater skid - 2 off shell & tube heaters in parallel

1st stage separator skid - Horizontal 3-phase vessel, 96 x 24

Interstage heater skid - 2 off shell & tube heaters in series

2nd stage separator skid - Horizontal 3-phase vessel, 60 x 20

Electrostatic coalescer skid - Horizontal vessel, 120 x 30

Crude oil cooler skid - Plate heat exchanger

Crude oil export pumps - Duty/standby twin screw type Export metering skid - Duty/standby turbine meters

Produced water cooler skid - Plate heat exchanger

Flare KO skid - Vertical 72 x 10 vessel c/w condensate return pump

Flare tip & panel - Rated for up to 20 MMscfd of gas

Overall operating weight (excluding interconnecting piping) circa 235 tonnes.

Please note that additional skids can be provided to meet project specific requirements such as

produced water treatment and increased oil export pressures. Expros Production Systems

would be pleased to evaluate this upon receipt of the required design conditions.

Typical Layout


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Typical Applications

exprogroup.com

This particular equipment package has been utilised on a range of projects - both on and offshore.

Shell Malampaya Extended Well Test

Expro was awarded the contract to supply topsides process equipment and

subsea facilities for Shell Malampaya Oil Rim extended well test. The oil rim was

appraised through a 150 day test, processing crude oil on the Atwood Falcon

semisubmersible drilling rig, and oil transfer through a floating hose to a

dynamically positioned storage tanker. The tanker was filled three times during the

test with a total of 1,938,000 bbls of export quality crude produced to storage.

Kufpec Oseil Temporary Production Facilities

PT Expro Indonesia was awarded a contract by Kufpec (Indonesia) Limited to

provide temporary production facilities and services for first oil production from

the Oseil field, located on the remote island of Seram in the far eastern province

of Indonesia. This allowed early production from the Oseil field while Kufpec

continued with installation of permanent facilities.

The project, undertaken by Expros Production Systems in Jakarta, required

processing of up to 12,000 barrels of sour crude oil per day; and assistance with

the loading of the crude to a storage tanker, provided by Kufpec.

Expro supplied all required operations and maintenance materials, safety and

control devices, experienced personnel and vehicles. Additional contract

variations were awarded to Expro for temporary production pipelines and a 40-

man camp.

Shell BS4 Extended Well Test

Shell do Brasil awarded a contract to Expro for supply of topsides process

equipment for their BS-4 extended well test in the Santos Basin, offshore Brazil.

The well test enabled Shell to resolve reservoir uncertainties, reducing these

uncertainties so that they could proceed more efficiently with full-field

development, test use of electric submersible pumps on the field, and to collect

data to help in the efficient design of future processing facilities to treat the heavy

oil from the field to marketable condition, and to aid in formulating appropriate

flow assurance programs.

The equipment was mobilised from Expros Batam base for transport to Niteroi in

Brazil, where topside pre-assembled units were assembled, ready for installation

on the Transocean Drillship Deepwater Navigator, in the Maua Jurong shipyard.

Typical Offshore Extended Well Test Application (semi-submersible

drilling rig)

Typical Onshore Early Production System Application

Typical Offshore Extended Well Test Application (Drill Ship)

modular equipment

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