CRUDE OIL PROCESS FACILITIES

This Process Design Basis document describes the essential minimum criteria, which shall be adhered to in the Process Design Facilities. It shall be supplemented by, and shall be read in conjunction with the Codes and Standards necessary to meet applicable Government, and other Regulatory and Statutory requirements. Together, this Design Basis and the specified Codes, Standards and Specifications shall constitute the requirements for the Process design of the Facilities.

Well Clusters

Wellhead 

most of Wellhead in will be a dual completion type.
Manifold 

Manifold of Production header and Test Header are provided in each Cluster.
Well Testing Facility 

A permanent well testing facility will be provided at Cluster A and mobile well test unit for other wells. Related test manifold shall have provision for the well testing connection. Pig Launcher and Receiver
Requirement of Pig Launcher installation will be determined as the result of the Pipeline Integrity Study. The pigging facility, if required, will be provided for temporary type package by using pressurized nitrogen for the kicking gas.

Block Station
Manifold

Manifold are equipped with Production Manifold that receives production fluid from well Clusters. If Pig Receiver is needed for production pipeline, a temporary type receiver package will be provided.

Feed Heater

Feed Heater will be installed in Block Station. Feed Heater will keep production fluid temperature around 130 degree Fahrenheit. Hot oil will be used as heating medium.

Production Separator
Production Separator will be installed in Block Station. Block Station separator will receive production fluid from Well Cluster. There will be two series of separator; high pressure separator (operating at 600 psig) and medium pressure separator (operating at 150 psig).

Crude Stabilization Unit
Crude Stabilization Unit contains of LP Separator with heater treater that will be installed Block Station to obtain product crude with 7.35 psia RVP and less than 100 ppmv  water content.

LP Separator receives product crude oil from MP Separator. The crude is thermally and electrolytically treated to improve the separation of water from crude oil. To avoid emulsion, an emulsion breaker is injected upstream of the LP Separator.

Crude Oil Day Tank

Crude oil from LP Separator will be sent to Crude Oil Day Tank to settle out rest of the dissolved water before sent the crude oil into storage tanks. Degasser Boot is installed at upstream of Crude Oil Day Tank to release the excess gas.

Vapor Recovery Unit
Vapor recovery unit (VRU) is a compression system to recover light hidrocarbon that are released from MP and LP scrubbers. Vapor pressure from both LP and MP scrubbers are increased and then combined with vapor from HP scubber and feeding to Gas Plant. VRU will be installed at Block Station with 2x100% (one unit standby) installed capacity.

Produced Water Treatment Unit

Produced water from MP/LP Separators Unit is routed into Produced Water Treatment Unit that will be installed at Block Station. This Unit will be vendor package that shall be capable to reduce oil content from 1000 to 5 ppmv. The skimmed oil will be pumped back to the LP Separator while the product water will be stored in a Produced Water Tank and then pumped to Water Injection Unit located at Block Station.

Water Injection Unit

To maintain reservoir pressure, a water injection system to the reservoir is considered to be installed and the injection will be done since the early production. Source water will be taken from Produced Water.

A Water Injection Unit will be installed in Central Processing Facility. Water will be pumped by Water Injection Pumps, metered, filtered to 10 microns and sent for injection into the water injection well. Water injection pressure of 2000 psig is considered at the wellhead. Three pumps having 50% capacity will be provided. Two mechanical filters will be provided with facility of isolation and maintenance.