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FPSO Production & Process General Overview. How does it work?
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FPSO Production & Process General Overview. How does it work?

Introduction to Petrobras's P63 Platform

This section provides an introduction to the P63 platform, its type, location and processing capacity.

Overview of the P63 Platform

  • The P63 platform is a floating production storage and offloading (FPSO) type.
  • It will be placed in the Papateha field in Campos Basin and will operate in water 1200 meters deep.
  • The platform has the capacity to process 22,258 cubic meters of oil and 55,644 cubic meters of water per day.
  • It also has a storage system of one million four hundred thousand barrels of crude oil.

Oil Processing

This section describes the process for oil processing on the P63 platform.

Oil Processing Steps

  • 66% of processed oil comes from TLWP P61 and is transferred through three flow transfer lines (FTLs).
  • The remaining 34% comes from eight satellite production wells, six of which are operating and two are reserves.
  • Oil from these wells is received in the Riser balcony area before being sent to production or testing manifolds.
  • Received oil at the P63 is sent to plate-type preheaters that increase temperature to facilitate flow in separation.
  • Afterward, it goes through a high-pressure degasser where gaseous portions are separated from liquid.
  • Liquid then goes through high-pressure separator which separates water and oil.

Reheating Process for Oil Separation

  • The oil is reheated using two types of heat exchangers: plate-type heat exchanger and shell-and-tube heat exchanger.
  • Plate-type heat exchanger heats up thermal exchange with produced water during separation process.
  • Shell-and-tube heat exchanger heats up with saturated steam until it reaches 140 degrees Celsius, which is the ideal temperature for final separation process.
  • From there, oil goes to low-pressure gas degasser where remaining gas is separated from liquid.
  • Liquid then continues to low-pressure separator which works the same way as high-pressure separator separating oil from water.
  • Gas-free oil continues to electrostatic treaters where remaining water is removed from oil with help of electric current.
  • Treated oil is cooled before being stored in storage tanks.
  • Before storage, treated oil passes through a metering system to verify that it meets specifications and then sent to storage tanks where it will remain until offloading ship arrives.

Off-Spec Oil Processing

  • Oil out of specifications will be sent to off-spec tank where by settling, the oil will be removed from top and reprocessed.

Gas Processing

This section describes the process for gas processing on the P63 platform.

Gas Processing Steps

  • Gas separated during separation process is sent to P63 platform compression system.
  • This system has capacity to compress 1 million normal cubic meters per day.
  • The process of gas on platform is used for energy generation and feeding boilers lift gas to facilitate flow from wells.
  • Only gas used for re-injection is sent to third compression stage.
  • Gas taken from low-pressure system is processed using booster system composed of screw-type compressor that operates using lubricating oil for machine refrigeration.
  • Purpose of this stage is adapting low pressure compression system conditions to main compression system.
  • All gas that has been separated enters main compression process where it goes through cooler before being sent to first and second compression stages.
  • During these stages, gas goes through scrubbers to remove any condensates resulting from cooling process and then continues to compressors.
  • Compressed gas is cooled again in coolers before going to dehydration system that removes humidity from the gas.
  • Gas initially passes through coalescing filters to remove suspended particulate material.
  • It then goes to adsorption towers which contain zeolite.

Compression Stage

This section explains how gas is compressed and processed on the platform.

Gas Compression

  • The gas first goes to a scrubber to remove any droplets of liquid that might remain before entering the main compressor.
  • The pressure of the gas increases from 80 bar gauge to 300 bar gauge in the main compressor.
  • The pressurized gas is cooled in a cooler and then sent either to a gas re-injection well or a gas lift system.

Fuel Gas Treatment System

  • The portion of the gas sent to the fuel gas treatment system is cooled in a multi-steamer heat exchanger with its fluid being used to cool the products obtained in the low temperature separation vessel.
  • Before entering the vessel, fuel gas goes through Jewel Thompson valves which considerably reduce its pressure causing cooling resulting in condensation of heavy hydrocarbons within the vessel.
  • Hydrocarbons are condensed and light gases, mainly methane, go to the top.
  • After going through multi-steamer heat exchanger, this light gas is sent to power generation motors while condensed gas from vessel is reheated and afterward sent for another condensate removal process before being sent to feed boilers.

Water Processing

This section explains how water is processed on FPSP P63.

Produced Water Treatment System

  • All produced water during oil processing on platform is sent to treatment system in module 51.
  • Water taken from high-pressure separator is sent to high-pressure hydrocyclones while water taken from low-pressure separator is sent to low-pressure hydrocyclones.
  • Water separated in two hydrocyclone systems is cooled until it reaches 80 degrees Celsius when it is sent to dissolved gas flotation vessels.
  • Remaining oil is removed in these vessels and treated water is analyzed before being discarded.
  • The water must contain less than 29 parts per million of oil by volume. If it meets this specification, the water is dumped into the ocean. If it does not, it will be sent to the produced water tank where through settling, the water will be dumped into the ocean.

Sea Water Treatment System

  • Seawater used for utility purposes on FPSP P63 is pumped into platform's sulfate reduction unit (SRU) through pumps in the hole.
  • The sulfate reduction unit reduces sulfate level in the water.
  • Initially, the water goes through three filtering stages first to remove large particles that are more than 80 microns and then to remove finer particles of five absolute microns.
  • After filtering, the water is pumped to be processed twice in Nano filtration membranes through which the water is forced to reduce its sulfate content.
  • Low sulfate water is sent to de-aeration tower which reduces amount of oxygen in the water.
  • Treated water is sent for processing through booster pumps which elevate pressure to nine bar gauge.
  • After processing, treated water goes to injection pumps whose purpose is to pressurize reservoir attenuating loss of energy caused by petroleum production.

Polymer Pilot Plant

This section explains how polymer pilot plant works on FPSP P63.

Polymer Production

  • The first polymer pilot plant used in Brazil will be installed on P63.
  • This plant produces a polymer solution that will be injected into the water injection wells to increase viscosity of injection water and consequent well conversion.
  • Polymer powder stored in an inerted silo from which it is transported pneumatically to polymer processing unit (PSU) where it is mixed with treated water from the SRU.
  • After mixing, polymeric solution is sent to four maturation tanks where it remains for 30 to 40 minutes to finish maturation.
  • After maturation, polymeric solution with a concentration of ten thousand parts per million is pumped by a set of two pumps in series, a metering pump and a high-pressure pot.
  • Finally, this 10,000 parts per million solution is pumped and mixed into the injection water through a static mixer which homogenizes the final solution.

Power Generation System

This section discusses the P63 power generation system designed to meet the electricity consumption requirements of platforms P63 and P61.

Composition of the Power Generation System

  • The power generation system is composed of three modules with a total capacity of 103 megawatts.
  • It is driven by six motor generators.

Fuel Types

  • The platform uses three types of fuel: fuel gas, processed crude oil, and diesel oil.
  • The type of fuel used depends on availability over the production platform's years of operation.

First Brazilian Offshore Construction Company to Build an FPSO

This section discusses how Quiton became the first Brazilian offshore construction company to build an FPSO from basic design to operation in its first three years.

Building an FPSO

  • Quiton built an FPSO from basic design to operation in its first three years.

Platform P63 Specifications

This section provides specifications for platform P63, which operates in the Papateja field in the Compost Basin in Rio de Janeiro.

Platform Specifications

  • Platform P63 is 334 meters long and 57 meters wide.
  • It produces 140,000 barrels of oil and 1 million cubic meters of gas per day.
Video description

Welcome to our channel! In this video, we dive into the world of FPSOs (Floating Production Storage and Offloading units) and how they are revolutionizing offshore oil and gas production. From extracting hydrocarbons deep beneath the seabed to processing, storing, and eventually offloading them to tankers, FPSOs play a pivotal role in offshore energy operations. We'll cover: 🔹 How FPSOs extract and process oil and gas. 🔹 The onboard storage and offloading process. 🔹 Key safety and environmental considerations. 🔹 FPSO systems like risers, turrets, and mooring. Join us as we explore the engineering marvels that keep the global energy supply chain running smoothly! Don't forget to subscribe for more insights into the offshore industry. #FPSO #OffshoreEnergy #OilAndGas #MarineTechnology Funfact: The first oil FPSO was built in 1977 on the Shell Castellon field, located in the Spanish Mediterranean. Today, over 300 vessels are deployed worldwide as oil FPSOs. Introduction to what a FPSO is: Wikipedia : https://en.wikipedia.org/wiki/Floating_production_storage_and_offloading Rigzone : https://www.rigzone.com/training/insight.asp?insight_id=299 Oil and Gas IQ : https://www.oilandgasiq.com/fpso-flng/articles/guide-to-floating-production-storage-and-offloading-fpso ----------------------------------------- If you would like to share further info on this facility, please leave a comment and we will update soonest. Offshore, Maritime and Energy Industry Channel : All data, video and copyright belong to respective owners. No Endorsement: Any references, links, or mentions of third-party products, services, or websites in this video are for informational purposes only. Such references do not constitute an endorsement or recommendation by the content creator. Third-Party Content: This video may include content from third parties, such as images, videos, music, or other media. The use of such content is either done under the principles of fair use, with appropriate permissions, or falls within the realm of public domain. If you believe that any content used in this video infringes upon your intellectual property rights, please contact us so that we can address the issue promptly.