This sector covers offshore applications such as drilling and production platforms. Constantly exposed to extreme weather conditions, they require equipment capable of withstanding saline atmospheres.
This sector covers offshore applications such as drilling and production platforms. Constantly exposed to extreme weather conditions, they require equipment capable of withstanding saline atmospheres.
Offshore applications:
Given the extremely high cost of production downtime, offshore equipment must also be wear-resistant and easy to maintain . An FPSO (Floating Production Storage and Offloading) vessel, for example, can produce up to 200,000 barrels of crude oil per day. At around $80 to $90 per barrel, a breakdown that shuts down the vessel’s production could result in a loss of revenue of more than $700,000 per hour.
Onshore applications:
In economic terms, these applications are more viable than offshore applications, as evidenced by the operation of some wells that produce only a few dozen barrels of oil per day.
However, they can become extremely large due to the networking of wells for production that can reach up to a million barrels of oil per day. This expansion is accompanied by other difficulties to overcome.
First, drilling rigs are typically mobile , with motors and pumps often mounted on skids for easy transport.
Secondly, due to the multiplicity of drilling towers in a network, a very advanced control system must be in place to ensure the regularity and uniformity of the flows coming from all the towers. On this specific point, the A2S instrumentation cabinets offer great flexibility because they can be custom-designed in accordance with precise technical specifications.
The need to maintain circulation also drives the need for wellhead motors and controls , which are under high pressure and must be able to withstand up to 1,400 bars.
This critical point must be closely controlled to ensure uniform pressure, which is done by motorized valves in the wellheads. CBDB A2S boxes are custom-made and used to control these valves. They allow pressures to be monitored at the same time and data to be transmitted to the control point.
Intermediate sector: transport, storage and partial processing
The difficulties here are related to the fact that the extracted product is not pure and often contains a mixture of oil, gas, water and sand which must be separated before transport or pipeline delivery to a storage unit.
This separation can be done in several ways depending on the type of oil or gas being extracted from the wells , and up to 4 processes are often required before the product is ready to be piped or transported. These processes require energy, which is often obtained from the product itself by using the gas.
Once separation is complete, the product can be transferred for storage; in the case of an offshore platform, separation often takes place on land, before pumping to storage depots. In the case of FPSO vessels, all operations take place on board, and the oil is then transferred to tanker vessels before being sent to storage depots.
This step is also that of counting for the calculation of invoices and taxes. Current counting processes are extremely precise and measure not only the quantity of oil produced, but also the density, viscosity, pressure and temperature, and in the case of gas, the amount of water vapor.
Oil is often pumped directly to the refinery, the starting point for downstream applications, but often needs to pass through a series of pumps to reach the desired pressure.
Specific requirements
Corrosion in saline environments (offshore platforms, FPSO, etc.)
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There are currently just over 700 refineries worldwide, competing to supply local and international markets with finished carbon-based products.
Refined products include:
Fuels – LPG, petrol, kerosene, diesel, gasoil and bunker oil.
Petrochemical raw materials – LPG, naphtha and aromatics.
Energy sources – LPG, kerosene, fuel oil and heating oil.
Special products – Lubricants, bitumen, coke, solvents and waxes.
Petrochemical raw materials – Synthetic fibers (polyamide), plastics (polyethylene, PVC).
Refining involves four stages including:
1. The first is distillation for separation into five groups of products: LPG, naphtha, kerosene, diesel, and atmospheric residue. This distillation process is carried out at high temperature. The higher the temperature, the higher the quality of the product.
2. The second step involves upgrading or reforming, which modifies the product at the molecular level, for example to transform low-octane naphtha into high-octane naphtha that can be used for gasoline production.
3. The third and fourth steps involve processing the product to remove impurities such as sulfur and blending the refined product into various marketable products.
The final stage is supply to the market which includes storage and transportation . In the case of aviation fuel, for example, it may be shipped directly to airports by road or rail to the airport where it will be stored before being transferred by tanker truck for the aircraft refueling.
All stages of the downstream process involve different needs to ensure the safety of personnel and the quality of the final product.
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