Managing Integrity and HSE in a 40 Years Old Installation

Abstract

TOTAL E&P Indonésie (TEPI) is the biggest gas producer in Indonesia, who also produces oil. At the time this paper is written, TEPI is operating six Production Sites, two Logistic Bases, seven Drilling Rigs, hundreds of Floating Vessels and thousands of Oil & Gas wells. Central Processing Area (CPA) is a site that produces oil with some free gas from 555 deltaic multilayer sand reservoirs of Handil field. The site was built 40 years ago with its peak production around 200,000 BPD of oil in 1977. Today CPA produces on average 16,000 B/D of oil and 30 MMsfcd of gas. From total 694 well strings, only about 20% of it is actively flowing; these well strings are spread over 65 clusters. Most of the oil wells are artificially lifted by pump or gas lift compressors. Facilities were added and adapted along with the needs, such as High and Low Pressure gas compressors and Gas Lift Compression unit. Several Enhanced Oil Recovery (EOR) projects had been tried, such as gas injection, air injection, and water injection. Currently the only artificial lift remaining is gas lift, and the EOR remain is water injection; the rests are stopped and modified. Nowadays, the main challenges of this mature field are integrity and HSE. Old design, obsolescence, modification of existing facility, and integrating with new technology generates several risks. Along with the maturity, leaks and potential leaks increase over time. The issues are corrosion, surface cracks, seepages, fugitive emission, obsolete equipment, increasing sand production, etc. Furthermore, several disused equipment also become another threat. This paper will discuss how CPA, a 40 years old Oil & Gas Production Installation, manages its Integrity and HSE. It will explain the challenges, good initiatives, and room for improvements. The topics will include Risk assessment & Identification, Inspection strategy, Integrity, Maintenance, Preservations, Work Permit implementation, Emergency exercise, etc.