This paper discusses challenges in developing high CO2 gas fields based on project execution of Tangga Barat Cluster, the very first high CO2 gas cluster being developed offshore Peninsular Malaysia by PETRONAS Carigali. Discussion focuses on the intricacy and challenges specifically on designing offshore facilities to accommodate one of the largest Acid Gas Removal System (AGRS) offshore. It addresses steps and considerations in decision making, reaching the most advantageous solutions, in designing the AGRS as well as the overall facilities which involves the required supporting utilities. Data from well tests, FORGAS simulations, and process model from HYSYS among others shall be woven in the discussion. The discussions on the executed design strategy shall benefit future high CO2 gas fields projects by providing at the very least, a design guidance. The paper highlights the modus operandi in ensuring the final gas specifications of 8 mole% CO2 is met while accommodating different AGRS technology provider utilities requirements. The membrane technology was identified for the bulk CO2 removal of 35% down to 8% CO2 in sales gas. Due to distinctive differences in the technology provider's removal processes, several factors were considered in designing the process utilities, electrical, mechanical and structural aspect of the system. The overall project economics for hydrocarbon losses in both single and two stage systems were assessed to reach a decision with acceptable losses. The operating conditions of the AGRS were optimized through the analysis of the reservoirs pressure and the booster compressor optimization. In view of the high development costs associated with these acidic fields, it is the author's intent to contribute, to some degree, lessons learnt in the planning, design and execution for future acidic field developments. It is aspired that through costs, time and resources optimization, the overall project economics can be improved. 1.0 Introduction The future offshore gas fields development in Malaysian waters shall see a rapid rise in the development of high CO2 gas fields, attributed by the fact that past focus has been on the conventional or "easy fields", which has now been producing for the last 20 - 30 years and is at various stages of depletion. As one of Malaysia's leading operators, PETRONAS Carigali Sdn Bhd was entrusted with the challenge of executing one of the first cluster of high CO2 gas fields, known as Tangga Barat Cluster (TB Cluster) to meet the Peninsular Malaysia Gas Utilization demand in Q4 2010. TB Cluster is located 185 km offshore East Coast of Peninsular Malaysia in the PM 313 Block at a water depth range of 60m to 70m. Consisting of Melor, Laho, Tangga and Tangga Barat fields, TB Cluster shall have a total of 27 producing wells.
Turbomachinery is recognized as one of the most important equipment in oil and gas facilities. Major issues identified are the monitoring of turbomachinery health condition; recognizing equipment failure patterns; reducing unplanned repair costs; ensuring uninterrupted production and avoiding unscheduled downtime. Thus, there is a need of innovative digital solution to address the highlighted issues. This paper will explain the transformation journey that has been endured by PETRONAS Upstream in crafting the journey in digitalizing the remote monitoring and operations for turbomachinery and major rotating equipment. The transformation journey started back in 2014 where the upstream assets were deploying various Original Equipment Manufacturer (OEM) remote monitoring solutions, which require additional hardware installation at site, significant capital expenditure and monthly subscription for each OEMThe strategy hit a setback when oil price went down which requires significant cost cutting measures. Applying the mantra of "Do More With Less", the asset collaborated with the Centre of Operational Excellence (CoE) to develop their own solution which was branded as Prescriptive Rotating Equipment Analytics (PROTEAN), which eventually replaced all OEM solutions in the long run. Defying the norm, all changed when the PETRONAS Upstream Operational Excellence team decided to embark on the digital journey by developing an in-house predictive analytics tool which is capable to identify anomalies trends, highlight potential incipient failures and identify opportunities for reliability improvement of the turbomachinery equipment. The pilot implementation was conducted in 2017 via implementation on 2 units of supercritical turbomachinery equipment. Following the the successful implementation, PROTEAN was upscaled and expanded to cover more than 200 units of major rotating equipment located at 23 offshore platforms, 6 onshore terminals located within Malaysia, International Assets as well as the world first Floating Liquified Natural Gas i.e. PETRONAS PFLNG Satu. PROTEAN+ provides a niche edge in supporting data driven maintenance, understanding the machinery deteroriation rate and justifying the extension of Mean Time Between Overhaul (MTBO). PROTEAN+ also provides the prescriptive analytics based on the Failure Mode and Effect Analysis (FMEA) of each specific rotating equipment. To date; PROTEAN has generated more than 700 alerts since 2017 resulting in USD50 Million of cost avoidance from unplanned production deferment and unplanned repair cost. The journey also covers the Technology Readiness Level (TRL) process which is vital in order to gain the confidence level from end users. As a conclusion, the paper will highlight the critical success factors and key lessons learned in a transformation journey for turbomachinery digital remote monitoring and operation. This paper shares the experience from the transformation journey on how the overall operating expenditure can be further optimised without sacrificing the technical functionality as well as sustaining the technical capability building. By understanding the key critical success factors in implementing the digital solution, it is a real life example on how to build your own business case when it comes to digitalisation and to avoid from creating another white elephant solution.
Turbomachinery is the heart of any platform, which generates power and compresses gas. However, the current practices of turbomachinery are entangled with various challenges and obstacles, which eventually affect the overall performance of the platform. Hence, this paper aims at appraising the challenges and obstacles in turbomachinery project execution for high CO 2 gas field. Via the literature review, this aim is achieved via its objectives of 1) reviewing the oil and gas industry in terms of its operation and project execution; 2) determining the basic attributes of turbomachinery as well as the challenges and obstacles entangling its execution; and 3) proposing the solutions to these challenges and obstacles. It is found that stabilized process requirement and constant flow; subsurface uncertainties; production decline; selection process; specification and standard variations; contractual delivery; human factor; after sales support and services; and expenditure are listed as amongst the challenges and obstacles in executing turbomachinery project for oil and gas. The findings of this paper would technically contribute to the project management elements of turbomachinery project execution and assist the management team particularly on the client/consultant side in efficiently and effectively manage the turbomachinery project execution via the prediction of challenges and obstacles. Index Terms-Challenges and obstacles, high CO 2 gas field, oil and gas industry, turbomachinery.
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