AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P – 10
MODULE SUBJ. : OIL PRODUCTION OPERATIONS

Tasks:

Overview of Production Operations

10.1 Use drawings to identify the whole production process. Give as much
details as possible.

10.2 Explain how the different production processes are linked together.

10.3 Explain how operational problems in a given area impact on other areas.

Central Control Room Operations

10.4 Monitor and control remote station operations

10.5 Control the gas to flare to optimise production

10.6 Start and Stop the Main Line Oil Pumps

10.7 Actuate telemetry shutdown of remote equipment and stations

10.8 Communicate and report on emergency situations

10.9 Communicate and report daily production data to supervisors

10.10 Communicate with other area CCR operators.

10.11 Know your responsibilities in a Black Start procedure.

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AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P10 Oil Production Operations

TASK NO. 10.1 Use drawings to identify the whole production

process. Give as much details as possible.
:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

OMAR NORTH/SHAHEL GATHERING STATION FACILITIES

- Wellheads and inlet manifold IM-101

The inlet manifold, IM-101, is the connection point in this plant for all the flowlines
from the Shahel and Omar North Oil Fields. IM-101 contains a set of four manifold
headers. Each of the 12 well positions is connected by a single valve to the manifold
headers. Each manifold header in turn, is connected to the drain system by a double
block valve with spectacle arrangement. The outlet to the process of the test, H.P. and
I.P. headers each contains a shutdown valve, to permit safe unmanned operation of the
facility.

- Test separator, V-102

The crude oil and water from a single well are diverted into the test header of the inlet
manifold and are thus directed to the inlet of the test separator, V-102.
V-102 is a three-phase separator, with flow meters on each of the outlet gas, oil, and
water streams. After metering, the crude oil and water streams are recombined for
insertion to one of the downstream separators either I.P. or FWKO. The separated gas,
after metering and pressure control, is sent directly to the gas plant via the coalescer. It
is high pressure gas. when the test separator is in I.P mode then the gas out of the test
separator is lined up to the I.P header third stage of the gas compressor, which is then
compressed and lined up to the HP. Header. Any excess gas is flowed to the Flare
Header.

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TASK: 10.1 Continued
The test separator is designed for testing wells at either high pressure or low pressure.
The test pressure, manually set on a local pressure indicating controller, has been
selected based on a 5 minutes retention time on the oil phase. The gas phase occupies
the upper half of the vessel. Internal separation device include a Schoepentoeter inlet
diverter, perforated baffle plates, a parallel plot pack and a vanepack in the vapour
section.

- H.P. Separator, V-103

High pressure wells from the OMAR North or Shahel areas are turned into the high
pressure header of the inlet manifold, by which they are directed to the H.P. Separator,
V-103.
V-103 is built as a three-phase separator but is equipped and operated as a two-phase
(gas/liquid) separator with the water outlet blinded.
The separated gas, after metering and pressure control, is the separated gas of the HP
separator. It joins the gas compressor discharge, which is then cooled in the fin fan
cooler, and flows via the coalescer to the gas plant. The combined oil/water outlet is not
metered and is controlled by the vessel oil level. The H.P. separator is designed for
operation at either high or lower pressure with emphasis intended for high pressure
operation. Internal separation enhancement devices are a Schoepentoetor inlet diverter,
perforated baffle plates, a parallel plate pack, and a vanepack demister. The adjustable
weir can be bolted in for three phase operation.
- I.P. Separator, V-104

The I.P. separator operates at a pressure significantly lower than the H.P. separator. The
feed to V-104 can come from either or both of two sources: the liquids from V-103 or
crude oil streams from the I.P. header of the inlet manifold. The liquids out of the test
separator will also usually be directed to V-104.
V-104 is built as a three-phase separator but is equipped and operated as a two phase
(gas/liquid) separator, with the water outlet blinded. The separated gas out of the I.P
separator join’s with the 2nd stage discharge of the gas compressor and via the fin fan
cooler goes into the 3rd stage suction scrubber.

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TASK: 10.1 Continued

The separated intermediate pressure gas is metered and under pressure controlled, while
the combined oil/water outlet is not metered and is controlled by the V-104 oil level.
The vessel is selected based on 5 minutes oil retention in the eventual configuration.

- FWKO Vessel, V-106 (No. 1)

Crude oil/water which is separated in V-104 flows to the FWKO vessel for low pressure
separation of gas and removal of free water from the stream, to allow metering of the
oil. Under some circumstances outlet liquids from V-102 test separator will be routed to
V-106. These test liquids will be from testing of low pressure wells and will not yield
large quantities of gas which might overburden the limited space in this separator which
is allocated for gas handing. The upper portion of V-106 is segmented in such a way that
there is a short gas separation space near the inlet and the rest of the vessel operates
liquid-packed as a settling/coalescing section. Internal separation enhancement devices
promote the coalescence and separation of water particles.

The separated gas from the front section of V-106 goes into the first stage of the gas
compressor suction scrubber. Any excess gas goes on to the flare header. Oil from the V-
106 outlet flows to the suction of the P-108 pumps. Water is withdrawn from V-106
through a perforated pipe collector and flows to the suction of the P-109 pumps.

- Oil transfer pump, P-108 A/B and water transfer pumps, P-109 A/B

These two sets of pumps are arranged so that an additional degree of operating
flexibility is obtainable. The P-108 pumps are each sized for 100 cu.m/hr., while the P-
109 pumps have a capacity of 40 cu.m/hr. each, with pumps of both sets discharging at
40 barg.

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TASK: 10.1 Continued

A level control valve on the discharge line of each set of pumps modifies the above
parameters to keep levels steady in V-106. The oil level control valve is downstream of
the LACT unit to maintain single phase flow through the metering station. When one of
the level control valves closes (or opens) to maintain level, a pressure control valve
opens (or closes) in response to the changed pressure and bypasses flow of that fluid
back to the V-106 inlet.

- LACT Unit, M-112

Product crude oil flowing from P-108 and its outlet level control valve goes then to the
LACT unit where the stream is strained, analysed for water content, sampled and
metered before being released to the product pipeline. Each of the two meter runs are
sized for 200 cu.m/hr., (30,000 BOPD). One meter and run is always a 100 percent
spare.

The two A.O. Smith positive displacement meters are each rated up to 200 cu.m/hr.
Output signals from each meter are directed to separate flow computers for
compensation calculations and totalisation read-outs. Another computer controls an 8"
X 12" X 4" meter prover which provides meter factors for the ranges of flow of oil
which are going through the meter. The prover utilises a motor operated 4-port diverter
valve to facilitate meter proving, after the individual meter run, valves are manually
aligned to direct flow through the prover.

A secondary function of this valve is to limit the maximum flowrate through the meter
by a user selectable value in the flow computer. On loss of air supply or control signal,
this PCV will fail open.

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TASK: 10.1 Continued

- Oil scraper Launcher L-119

After being withdrawn from V-106 and increase in pressure to 40 barg by P-109, the
water passes through the interface level control valve LV-106A. The water stream then
recombined with the oil stream leaving the LACT unit skid. The combined oil/water
stream then flows to the L-119 scraper launcher for the 8-in. pipeline which transports
the OMN/SHL GS product oil stream to station GSA. The launcher’s design pressure is
46.55 barg at a temperature of 93.3oC and has a 10-in. barrel designed to ANSI standard
B31.8. A plant ESD valve is included downstream of the launcher.

- Flare system V-114, M-114, M-118

All process gas disposal and process relief valves discharge gas to the 18-in. flare
header, which is sized for both normal and process upset conditions. Gas in the header
flows to the Flare Knockout Vessel, V-114, where hydrocarbon liquids are removed by
settling.
V-114 is designed for 3.5 barg at 93.3 oC. Separated liquids gravity-flow to the closed
drain vessel through a level control valve regulated by liquid level in V-114. Gas exits
V-114 in a second 18-in. header and is routed to the base of the flare stack. The Flare
Stack, M-117, is overall 120 feet tall. It is tipped with a multiple-jet burner assembly
which widely disperses the burning gas, given a more intimate mixing with combustion
air for smokeless operation. Continuous burning is assured by a set of 3 flare pilots
which have a separate gas source. The pilots are lit by a Flame-Front Generator, M-118,
through ignition lines.

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TASK: 10.1 Continued

- Sumps and Drains
The clean-up pit have the purpose of handling the fluids in flowlines and well strings on
initial start-ups, to prevent putting foreign materials into the process piping and
equipment. Also, this clean up operation allows the flowline to be warmed, permitting
the separators to begin operation with oil near the design temperature. When the oil
level in S-101 triggers the level switch, the one clean up pit sump pump which is set on
“AUTO” will come on and begin pumping the oil from the sump and pump the oil to the
FWKO vessel.
The Utility Drain Sump, S-135, is connected to the open drain system, which collects
the skid drains, such as gauge glass drains and sludge draw-offs, and equipment drains.
When the level in S-135 triggers the level switch, the one (of two) utility sump pump
which is set on “AUTO” will come on and begin pumping oil and/or water from the
sump. P-134 A/B are rated at 5 cu.m/hr. each and pump the fluids to the closed drain
header. The utility drain sump is protected by an automatic CO2 fire snuffing system.
All the process vessel drains, manifold drain header, flare knockout drain and sumps
fluids are collected in V-115, the closed drain vessel, located to the north of the process
area towards the flare area. Any gas pressure in V-115 is vented to atmosphere at a
standpipe located in the flare area which is fitted with a flame arrestor. The vent also is
fitted with an automatic CO2 fire snuffing system which is activated by a detector
located at the vent.
- Utility water system
The utility water system at OMN/SHL GS consists of an 80 cu.m (500 BBL) storage
tank, unloading pumps, supply pumps and a 3-in. distribution header to 1-in.
Utility stations.
Raw water is trucked to OMN/SHL GS and unloaded at 20 cu.m/hr. by utility water
unloading pumps, P-132 A/B, into the utility water tank, T-131. Water is withdrawn
from T-131 by the primary utility water supply pump, P-133 A or B, and pumped
continuously to the distribution header. A constant pressure on the header is maintained
by a pressure control valve, PV-133, which releases water back to T-131.

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TASK: 10.1 Continued

- Instrument and Utility Air Systems

All air users in OMN/SHL GS are supplied by the 202 cu.m/hr. (119 CFM) instrument
air compressors, C-130 A/B, via V-120, the instrument air receiver. Pressure switches at
the receiver cause the compressors to cycle on and off to maintain the pressure there
between 6.89 and 9.31 barg (100 and 135 psig).

Separate outlets from the air receiver direct the compressed air to either the utility air
system or to filtration, drying, filtration and the instrument air header. Relief valves in
the system will relieve at 10;.3 barg (150 psig). A low system pressure of 5.2 barg (75
psig) in the instrument air header will trigger an ESD shutdown which will also be
annunciated at CPF/T field office.

- Fuel Gas System

The fuel gas system at OMN/SHL GS consists of a tap on the H.P. gas at V-103 and a 2-
in. line to M-118 flame front generator panel. Fuel gas is used there to ignite the flare
pilots and to provide continuous fuel gas to run the gas engine of the gas compressor.

- Chemical injection

Two chemicals to be injected at OMN/SHL GS, separately,a demulsifier and a corrosion

inhibitor chemical.
Demulsifier / corrosion chemical are injected into each of the three production headers
of the inlet manifold.

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AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P10 Oil Production Operations

TASK NO. 10.2 Explain how the different production processes are
linked together.
:

Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

Again with reference to Omar North , Shahel as in Task 10.1.

1. The oil process

2. The gas compression and condensate metering.
3. The glycol dehydration.
4. Fuel gas system.
5. The oil metering and prover unit.

As the oil from the well’s arrive at the station manifold, they are diverted to the
respective vessels, Test, HP or IP to degas the oil as much as possible before metering.
The high Pressure Gas (HP) flows via a fin fan cooler to the coalescer directly to the gas
plant. The HP gas is scrubbed in the coalescer for condensate and water.

The gas compressor takes in the L.P (low pressure) gas via the cooler as shown in the
attached drawing. All the gas coming into the gas compressor suction/discharges are
cooled at the fin fan cooler, except the third stage discharge which goes directly into the
4th stage suction without cooling and the 4th stage/compressor discharge ties in with the
HP gas before it enters the fin fan cooler.

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TASK: 10.2 Continued

The Glycol dehydration is used mainly to prepare fuel gas to run the gas compressor,
and dehydrate the export gas to the gas plant. As the line does not have a H.D.P.E liner
(high density polyurethane liner) to project it internally.

The fuel gas system is only for the gas engine of the gas compressor.

All the crude out of the station is metered and there are two metering skids, one is on
duty while the other is on stand by.

The prover is used once a month to check the meter correction factor of the on-line and
off-line meter’s. It is updated in the flow computer to maintain the accuracy of the
meter.

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MODULE NO. : P10 Oil Production Operations

TASK NO. 10.3 Explain how operational problems in a given area

impact on other areas.
:
Reference: AFPC manual and respective P&IDs
Requirement – By Trainees : Trainee must become familiar with the production
operations and controls

An example of how operational problems in a given area impact on other areas is as

follows:
If the Omar power plant for some unforeseen reason has a total outage -all three power
generators trip – it is not only the power plant that will have problem’s. Omar C.PF will
also trip. All the out station’s will shut down. Tanak field will trip.
Tanyem field will trip.
Gas Plant will trip
and all the pressure reducing Stations at Damascus may also be tripped if SPC is not
able to back up the feed gas.

This chain reaction is all caused because of the Omar power plant failure.

This is how a trip in one plant can seriously impact several other plants.

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AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P10 Oil Production Operations

TASK NO. 10.4 Monitor and control remote station operations

:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

Where the DCS system is not available you can only monitor the out station
parameter’s. All the control’s are localised.

For example any well changes -bean up’s or bean down’s- must either be done at the
station or the well site. If any well has to be tested then the operator has to go to the
station and make the desired adjustment.
Also any change over (weekly) of equipment eg. pump’s or air compressor’s have to be
done locally. Chemical rate checks must be done locally at the station itself.

From the Omar CPF we can shut down any of the outstation’s by telemetry.

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MODULE NO. : P10 Oil Production Operations

TASK NO. 10.5 Control the gas to flare to optimise production

:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

Operations and controls

At Omar North, Shahel or any Gathering station, care must be taken to optimise the
production. To achieve this, you should be aware of the cause and effect’s of the overall
process.

For example in the Gathering station the HP pressure is the plant pressure. This should
be checked and monitored continuously during an operators shift. To fully optimise oil
and gas production the operator must maintain this pressure at the recommended value.

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AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P10 Oil Production Operations

TASK NO. 10.6 Start and stop the main line oil pumps

:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

For Gathering Station operations:

 Check the pump discharge and suction SDV’s and block valves are lined up.
 Check the power to the pump.
 Ensure that the pump protection systems on line.
 Check the level in the surge vessel.
 Start the pump
 Monitor the flow
 Control the level by adjusting the transmitter / controller for the discharge control
valve.

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MODULE NO. : P10 Oil Production Operations

TASK NO. 10.7 Actuate telemetry shutdown of remote equipment

and station.
:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

Operations and controls

Telemetry shut down is the loss of the 24 volt DC supply at the plant. This can be
initiated from a distance. For example a central control room operator at the CPF can
actuate a telemetry shut down for a remote/distant out station.

The telemetry S/D basically causes an electrical ESD in the plant as all the process
plant’s will lose the 24 volt D.C supply.

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MODULE NO. : P10 Oil Production Operations

TASK NO. 10.8 Communicate and report on emergency situations

:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

It is the duty and responsibility of every operator/senior operator to communicate and

report any incident or emergency situation.
All plant upset conditions must be immediately reported to the plant supervisors.
By involving supervisors immediately, upsets can be quickly corrected.
This will result in a safer and more efficiently run operation.

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AL FURAT PETROLEUM COMPANY TASK DETAILING MANUAL

MODULE NO. : P10 Oil Production Operations

TASK NO. 10.9 Communicate and report daily production data to

supervisors
:
Reference: AFPC manual and respective P&IDs

Requirement – By Trainees : Trainee must become familiar with the production

operations and controls

It is an every day responsibility to communicate and report on the daily production data
to the supervisor’s to help maintain proper production target’s.

For example, if a supervisor has beaned up a particular well at the well site/well head
and he request’s the station operator to carry out a well test.
He needs to confirm that the desired rate has been achieved at the end of the shift
If the operator does not communicate with the supervisor and pass on the relevant data,
then the supervisor will experience a deficiency in production or increase in production
which will be reflected in the daily production report.
This can be avoided if the station operator communicates and reports the production
data promptly.
The supervisor can then make further adjustments to achieve the targeted production
rates.

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