Surface Fluid Handling System: Consideration for Process Safety Design

摘要

As the industry has moved toward more complex wells/environments (i.e., high pressure, high temperature with challenging geological aspects), this paper presents considerations for process safety design for the venting capability of the surface fluid handling system, including overboard lines, mud gas separator main vent line, and anti-siphon vent line. As kicks may become larger due to higher pressure reservoirs, venting safely has become a point of emphasis for process safety. This paper focuses on gas venting capability by defining the safe operating and design limits of the system through the analyzing kick and venting scenarios. This paper proposes an updated calculation methodology to the sizing of the surface fluid handling system. It also brings considerations for design parameters to achieve safe venting conditions. Hazard identification techniques were used to analyze scenarios related to handling hydrocarbon at the surface during well activities. Once the potential hazards and scenario were identified, this allowed to calculate safe operating limits using operational and design parameters, and provides guidance on how to mitigate the potential risks during a circulation of the kick. Furthermore, we discussed the potential limitations of venting capability as the industry is entering in the ultra-deep and high pressure high temperature reservoir. This paper aims to increase the understanding of application of process safety engineering to well activities. The work shows a novel approach to managing risk through design by better understanding of limit operability of the rig systems combined with a simple management system approach for sustainability.