Integrated Water Re-injection

Plant for Enhanced Oil Recovery

(Onshore Oilfields)

Copyright © Siemens AG 2010. All rights reserved.

Integrated Water Re-Injection Plant
Scope of Siemens Oil & Gas

Page 2 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Intelligent Water Re-injection Plant
Concept and Approach

Standardized components to provide

customized but flexible solutions

Pre – engineered
 Solution Packages
 Skid mounted equipment and ready to use
 Connecting Pipes
 Electrical Wiring and Instrumentation
 Control Center
 Modules (for single, parallel or sequential arrangement)

Page 3 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Plant Diagram

Produced
Water Produced Water Oil & Solid Removal Skids Processed Water
from Surge Drum Skid  1 set L-S Hydrocyclone Surge Drum Skid
GOSP  1 set S-S Hydrocyclone
 1 set DGF (Veirsep-PTM)
 1 set Walnut Shell Filter
 2 set Pump Skids
Electrical Power System

Instrument Air System

unmanned Operation
Telecommunication

Injection Pump Skid

Air Compression
Piping & Layout
Control System

Manned versus
 variable speed drive system
Automation &

 high pressure

Laboratory
 including lube oil system

Station

Make Up Water
Water Conditioning
 Sea Water
 Coarse Filters Make Up Water
 Fresh Water
 Fine Filters Balance Tank
 River Water
 Deoxy Vacuum Tower WELL HEADS
 Ground Water

Page 4 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
 Integrated Water Re-injection Plant
Pre-engineered produced water reinjection

Siemens WRI solution to be perfectly Requirement needed from Customer:

balanced between meeting client Water inlet and outlet specification
requirements, product standardization
and manufacturing time. Designed to
plug’n play.  Pre – Engineered Solution Packages water
injection 20 … 40 … 80 k BWPD
 Injection pressure range 50 – 250 bar
Standardized  Oil and Solid Removal < 10 ppm
Module
GT  Skid mounted equipment ready to use
Package
 MW range up from 0,5 MW – 4,0 MW
E&A  Ex Zone Classification 1 and 2
Container
Hydro  Oil & Gas proven standardized components
cyclone Treated
In
Water Tank
(API, ASME, EU)
Flotation
 Delivery in ca. 12 -18 months,
Pump all from one source
Walnut
Skid
Shell Filter  Plug ‘n play during commissioning
 Totally unmanned operation
 Full maintenance and operation service
Artificial view

Page 5 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Environmental Conditions

Arctic environment (Russia) Desert environment (Libya)

 Plant design for -40° Grad Celsius  Plant design for up to 60° Grad Celsius
 Heating tracing system for complete plant  Tropicalization of the electrical equipment
 Isolation according to client spec. and instrumentation
 Gost and RTN Certification  Housing and shelter
 Ready for train transport  Ready for ship transportation
 Bilingual documentation
Page 6 Claudio Ranaudo
Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Lifecycle Management - Comprehensive View

PLANT LIFE CYCLE Comprehensive

over view LIFE CYCLE
Preservation MANAGEMENT
Mechanical COVERS
INSTALLATION PHASE
Engineering & Project Completion
Management Clear punch list
Documentation
Planning
Procurement, FAT
Delivery COMMISSIONING Functional checks
ENGINEERING/ PHASE
testing & commissioning
PROJECT PHASE Putting to operation,
Training, SAT,
Completion, As built
drawings, Training
Solutions, systems,
Feed stage,
Documentations, Bid OPERATION
Management, PHASE Startup support
FEED/EPC Warranty, On call
Purchase order
PHASE service Preventative &
Planned maintenance,
Repairs, Training,
Upgrading & Retrofitting

Page 7 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Unique Selling Points (1)

• Plant is designed and engineered in a modular manor, e.g. skid mounted, standard

equipment, etc.

• Plant units are configurable and scalable, e.g. by means of modular concept

• Plant is designed and engineered for unmanned operation, if applicable

• Plant is supplied “turnkey”. This includes design, engineering, procurement, installation,

commissioning, and maintenance services, as well as Siemens Project Management

expertise, if applicable

• Siemens equipment and systems are included in design and engineering as thoroughly

as possible

Page 8 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Unique Selling Points (2)

•All actuators for control equipment shall electrically operated and compliant to e.g. ATEX

specification, SIL requirements, etc.

• Remote I/Os are installed per Unit / Skid and e.g. skid mounted. For instance, there shall

be one cabinet on skid containing power supplies and I/O modules

• DCS and SIS integrated

• All process pumps are driven by VSDS in order to increase energy efficiencies and to

minimize CAPEX and OPEX

• Plant is designed and engineered for Remote Service e.g. in order to optimize Plant

availability and spare part warehousing with respect to OPEX

Page 9 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
 Integrated Water Reinjection Plant
Our Value Proposition

Fast ROI
 Standardization

Risk Reduction
 “one-throat-to-choke”
 World-class products
 Project management and execution

Short Project Execution Time

 Pre-engineered packages

Flexibility
 Modular design
 Transportable modules
 Leasing model available
 Support testing and analysis of
reservoirs

Page 10 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Hypothetical example for WRI Plant
20.000 bpd, 150 bar, approx. 1,1 MW

Hydro- Flotation Walnutshell Water Surge Pump Skid

cyclone Filter Drum

Siemens/ Siemens/
Siemens Siemens Siemens
external external

LxBxH: LxBxH: DxH: DxH: LxBxH:

6mx2,5mx2,5m 10mx3mx2,1m 3,3mx7m 12mx3mx3m 10mx2,5mx3m

6 months 10 months 8 months 6 months 12 months

2 process pump
1 Skid 1 Skid 1 Skid 2 Skids skids, 1 injection
pump skid

Page 11 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Hypothetical example for WRI Plant
20.000 bpd, 150 bar, approx. 1,1 MW

GT Package Alternatively E&A/Comm. Eng., Pro-

Diesel Gen. Container curement, PM

75 % Siemens
Siemens External Siemens Siemens
25% External

LxBxH: LxBxH: DxH: Foot print

n.a.
6mx2,5mx2,5m 6mx2,5mx2,5m 6mx2,5mx2,5m 250 m²

12 m. of delivery
12 months 12 months 4 months 6 months after PO + 2 m.
inst./comm.

1 Skid 1 Skid 1-2 Skids n.a. 11-12 Skids

Page 12 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Actual Project

End User: ZADCO (ADNOC)

Overview:

- 400.000 BWPD ~ 2650 m³/hr

- 5 trains with around 100.000 BWPD Plants
- 4 trains in operation and 1 train in stand by
- Increasing of the injection water over 25 years up tp 1.2 mio. BWPD

Important for the Customer:

- Less capex
- flexibility during the lifetime
- easy to integrated a additional train in the existing plant (instrument,
electrical, control and automation system)
Page 13 Claudio Ranaudo
Copyright © Siemens AG 2010. All rights reserved.
Contact

Claudio Ranaudo
Research and Development
E O C&S ONS TI

Stintzingstraße 24
91052 Erlangen

Phone: +49 (9131) 18-2531

Mobile: +49 (173) 368-5707

E-mail: [Link]@[Link]

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Copyright © Siemens AG 2010. All rights reserved.
We are happy to answer your questions!

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Copyright © Siemens AG 2010. All rights reserved.
Back Up

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Copyright © Siemens AG 2010. All rights reserved.
Water Re-injection Plant
Product Sheet – Injection Pump Skid

Water Injection Pump

 Flow up to 20.00 – 60.000 BPD
 Heads up to 2500m
 Discharge pressure
up to 250 bar
 Temperature up to 450°C
Pumps: WCC
API 610 code: BB5  Speeds up to 6000 RPM
 Variable Drive System

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Copyright © Siemens AG 2010. All rights reserved.
Water Re-injection Plant
Product Sheet – Injection Pump Skid II

Optional WCC Shearing Design

 Quicker dismantle
 Easy maintenance
 Full cartridge design
 Applicable technology
 Suitable for Water Injection

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Copyright © Siemens AG 2010. All rights reserved.
Water Re-injection Plant
Product Sheet – Hydrocyclone Skid

 Liquid/liquid, solid/liquid designs

 Maximum separation in a small
footprint
 Low weight, important in offshore
applications
 Hydrocyclone bundles recently
patented
 Used primarily to remove
concentrations of oil
(200 to 2,000 ppm) from
Produced Water as an initial
separation step prior to polishing
by flotation systems
Page 19 Claudio Ranaudo
Copyright © Siemens AG 2010. All rights reserved.
Water Re-injection Plant
Product Sheet – Flotation Skid

 Liquid and solid removal from

produced water
 Maximum separation in a small
footprint
 Low weight,
 Solid and oil removal up 20 ppm
 Low maintenance cost and long
life time
 Air or gas flotation system
 Operated under pressure or
atmospheric conditions

Page 20 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Water Re-injection Plant
Product Sheet – Wallnut Shell Filter Skid

Tertiary Produced
Water Separation
 Walnut Shell Filters
 Media Filters
 Cartridge Filters
 Activated Carbon Filters
Advanced Treatment
 Biological Treatment
Solids Handling
 Gravity Thickeners
 Filter Press
 Belt Filter Press
 Sand Jetting Systems
Oil and Waste Recovery
Page 21 Claudio Ranaudo
Copyright © Siemens AG 2010. All rights reserved.
Power Supply

Gas Turbine Generator Combined Mechanical Drive

Nominal Rating Set Cycle Output KW BHP SPEED
At ISO, Gas Fuel MW(e) MW (RPM)

4,35/4,70
SGT - 100 4,922 6,600 13,000
5,05/5,25

SGT – 200 6,75 7,680 10,300 10,950

SGT - 300 7,90

SGT - 400 12,9 17,2 13,400 18,000 9,500

Page 22 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Oil & Gas Production
Produced Water Treatment Process Map

Primary Secondary Tertiary

Produced Solids Produced Produced Produced Discharge
Water Separation Water Water Water or Reinjection
Separation Separation Separation for
Water Flood

To Discharge,
Chemical Advanced Reinjection
Feed Treatment or Reuse

To Disposal

VOC Auxiliary Solids

Control Equipment Handling

Page 23 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Oil & Gas Production
Water Injection/Reinjection Process Map

Well or
Surface Coarse Fine Solids To
Water Screening/ Separation/ Deaeration Injection
Strainers Filtration Sulfate
Feed
Removal

To
Polymer
Or Steam
Chemical Feed Softening Flood
Systems Systems

To
Disposal

Chlorine
Solids
Generation/
Handling
Feed Systems

Page 24 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Oil & Gas Production
Water Injection/Reinjection – Case Study

 End User:
Saudi Aramco Company
 Application:
Oil Field Water Floods.
 Location: Qurrayah Seawater
Filtration Plant, Saudi Arabia
 Scope: Sea Water Media Filters
(20 and 36) and
Electrochlorination Systems
 Flowrate: 2.5 million bbl/day and
4.0 million bbl/day
 Year: 2004 and 2006
 Order Value: $10,500,000.00
Page 25 Claudio Ranaudo
Copyright © Siemens AG 2010. All rights reserved.
Power Generation Set – SGT 100

Lubrication
Oil Module Gas Fuel Auto Drain
DLE Module Module
(with ECU)

Liquid Fuel
Purge Module

Liquid Fuel
Supply Module
back

Page 26 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
 Integrated Water Re-injection Plant
Process Flow Diagram
20.000 BWPD Flowrate

Page 27 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
P&I Diagram Produced Water Surge Drum

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Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
P&I Diagram Pump Skid 1

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Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
P&I Diagram Walnut Shell Filter Skid

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Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
P&I Diagram Injection Pump Skid

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Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Single Line Diagram

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Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
System Architecture Diagram

Page 33 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Plant Layout Drawing

Page 34 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.
Integrated Water Re-injection Plant
Benefits for Customers

Page 35 Claudio Ranaudo

Copyright © Siemens AG 2010. All rights reserved.