TECHNICAL REPORT

ON
STUDENT’S INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)
UNDERTAKEN AT
NIGERIA NATIONAL PETROLEUM COMPANY EXPLORATION
AND PRODUCTION LIMITED (NEPL)

OGBA ROAD, BENIN-CITY, EDO STATE, NIGERIA

PRESENTED BY
ADAMS OHUNENE ABIGAIL
22/ENG07/012
SUBMITTED TO
DEPARTMENT OF CHEMICAL AND PETROLEUM ENGINEERING
COLLEGE OF ENGINEERING
AFE BABALOLA UNIVERSITY, ADO-EKITI, EKITI STATE NIGERIA
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
AWARD OF A BACHELOR OF ENGINEERING (B.ENG.) DEGREE IN
PETROLEUM ENGINEERING
SEPTEMBER 2024
 DECLARATION

I, ADAMS OHUNENE ABIGAIL (22/ENG07/012), hereby declare that the information written
in this SIWES report is correct and written according to the knowledge acquired during my
training period at the NIGERIA NATIONAL PETROLEUM COMPANY EXPLORATION
AND PRODUCTION LIMITED (NNPC E&P LIMITED).

………………………………….... ……………
ADAMS OHUNENE ABIGAIL DATE

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 CERTIFICATION

This is to certify that this work titled Student’s Industrial Work Experience Scheme (SIWES)
was undertaken at Nigerian National Petroleum Company Exploration and Production
Limited (NNPC E&P LTD) by Adams Ohunene Abigail with student matriculation number
22/ENG07/012 and presented to the Department of Chemical and Petroleum Engineering,
Afe Babalola University, Ado-Ekiti, Nigeria during the 2023/2024 Student’s Industrial Work
Experience Scheme (SIWES).

Engr. Dr. O.Adesina

Head of Department Signature and Date
Chemical & Petroleum Engineering

Engr. Dr. Ogunyemi Adebayo

SIWES Coordinator Signature and Date
Chemical & Petroleum Engineering

ii
 DEDICATION

This report is dedicated to Almighty God and my parents Mr and Mrs Adams for
their unconditional love and support during the course of my program.

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 ACKNOWLEDGEMENT

I want to appreciate Almighty God for giving me the grace, opportunity and strength to
complete my SIWES program successfully.
I want to thank my Parents Mr and Mrs Adams for their unwavering support, encouragement
and prayers and the family of Mr and Mrs Ogundeji for their encouragement, support,
prayers and hospitality.
I thank my school for allowing me to partake in such a thrilling and amazing work
experience.
I also want to thank the management of NNPC E&P LIMITED for providing me with the
opportunity to gain practical experience in the oil and gas industry for (6) months. Most
especially Mr Maaman Musa the HOD for OML 98, Mr Saleh Babangida my industry based
supervisor and other OML 98 and EXPLORATION STAFFS for their continuous care,
dedication and support in making me a better student and expanding my horizon.
Lastly, immense gratitude goes to my fellow interns for making my stay at NEPL
exciting and also for the little office sessions we have with each other from time to time
and to my friends in person of Makama blessing and Bayo for always encouraging me.

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 ABSTRACT

The introduction of students Work Experience Program (SWEP) into the normal school
curriculum has opened up an avenue for students to acquire a lot of experience, skills,
information and knowledge during the period of attachment to the company/ industry in order
to supplement the theoretical background of their chosen course of study and also to prepare
them for the challenges the future holds.

This comprehensive report documents my six-month Students Industrial Work Experience

Scheme (SIWES) program at NNPC E&P, OML 98. The program aimed to provide practical
experience in the oil and gas industry and enhance my employability skills. During my
tenure, I worked on various projects, including the IWCF program, and participated firsthand
in the production process at the flowstations and gas plants I was privileged to work at.

This report commences with an overview of the Students Industrial Work Experience Scheme
(SIWES), and proceeds to provide a concise history and organizational structure of the Nigerian
National Petroleum Corporation Exploration and Production (NNPC E&P) as well as an
overview of OML98, the department I was deployed to. Following this, the report delves
into a comprehensive theoretical framework of the tasks and activities done, juxtaposed with
a detailed account of the actual work executed during the internship period.

Lastly, no experience can be said to be worthwhile without one experiencing some challenges
and overcoming them. During the course of the work, the challenges I faced is clearly stated
here and some recommendations which I have come up with to make the SIWES program better
would be stated.

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 TABLE OF CONTENT
DECLARATION.........................................................................................................................i
CERTIFICATION...................................................................................................................... ii
DEDICATION.......................................................................................................................... iii
ACKNOWLEDGEMENT........................................................................................................ iv
ABSTRACT...............................................................................................................................v
CONTENT................................................................................................................................ vi
LIST OF FIGURES................................................................................................................ viii
ABBREVIATIONS AND KEYWORDS..................................................................................ix
CHAPTER ONE........................................................................................................................ 1
INTRODUCTION......................................................................................................................1
1.0 HISTORY OF SIWES......................................................................................................1
1.1 OBJECTIVES OF SIWES………………………………………………………………1
1.1.2 BODIES INVOLVED IN THE MANAGEMENT OF SIWES.................................... 1
1.2.1 BRIEF HISTORY ABOUT NNPC E&P LIMITED..................................................... 2
1.2.2 OVERVIEW OF NNPC E&P LIMITED...................................................................... 3
1.3 ORGANOGRAM AND RESPONSIBILITIES............................................................... 4
1.3.1 NNPC LIMITED ORGANOGRAM....................................................................... 4
1.3.2 NNPC E&P LIMITED ORGANOGRAM.................................................................... 5
1.3.3 Responsibilities of Departments................................................................................... 5
1.4 SUMMARY OF INTERN’S ROLES/RESPONSIBILITIES AND ACTIVITIES;........ 8
1.5 SUMMARY OF WORK DONE AND DETAILED INTERN’S
ROLE/RESPONSIBILITIES AND DAILY ACTIVITIES........................................................9
CHAPTER TWO..................................................................................................................... 11
THEORY BEHIND WORK DONE........................................................................................ 11
2.1 Field Activities............................................................................................................... 11
2.1.1 Definition of an Oil Field............................................................................................ 11
2.1.2 Flow Station................................................................................................................ 11
2.2 OFFICE ACTIVITIES................................................................................................... 27
CHAPTER THREE..................................................................................................................30
ACTUAL WORK DONE / EXPERIENCE GAINED............................................................ 30
3.1 OML 111 and 98 Flowstation Field visit........................................................................30
3.1.1 FST-1 PROCESS FLOW............................................................................................ 31
3.1.2 FST-3 PROCESS FLOW............................................................................................ 33

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 3.1.3 INTEGRATED GAS HANDLING FACILITY (IGHF).............................................34
3.2 SEPLAT JV Field visit................................................................................................... 36
3.2.1 THE BOOSTER STATION........................................................................................ 36
3.2.2 THE GAS PLANT...................................................................................................... 37
3.2.3 DI-ETHYLENE GLYCOL (DEG) UNIT................................................................... 39
3.2.4 THE WELLHEAD......................................................................................................39
3.3 HSE (HEALTH, SAFETY AND ENVIRONMENT..................................................... 41
3.4 OFFICE ACTIVITIES................................................................................................... 43
3.4.1 Production Monitoring................................................................................................ 43
3.4.2 Introduction to Drilling (Learn to Drill) course.......................................................... 45
3.5 Experience Gained......................................................................................................... 46
CHAPTER FOUR....................................................................................................................47
CONCLUSION AND RECOMMENDATIONS..................................................................... 47
4.1 Conclusion......................................................................................................................47
4.2 Recommendations.......................................................................................................... 47
REFERENCES.........................................................................................................................48

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 LIST OF FIGURES
Figure 1. 1: NNPC BUILDING 3
Figure 1. 2: NNPC ORGANOGRAM 5
Figure 1. 3: DEPARTMENTS REPORTING TO EVP UPSTREAM 7
Figure 1. 4: OML 98 HIERARCHY 7
Figure 2. 1: SKETCH OF A PETROLEUM PRODUCTION SYSTEM 12
Figure 2. 2: DIAGRAM OF A WELLHEAD 13
Figure 2. 3: A sketch of a Christmas tree 14
Figure 2.3.1 Picture of me beside a Christmas tree 14
Figure 2. 4: Diagram above represent cellar pit that is covered 15
Figure 2. 5: Arrival manifold showing valves 16
Figure 2.5.1 Picture of me at the manifold showing valves 17
Figure 2. 6: Internal Feature of a test Separator 18
Figure 2. 7: Picture of a Test Separator 19
Figure 2. 8: Diagram representing flow analyser 20
Figure 2. 9:DIAGRAM OF A DEGASSER 21
Figure 2. 10: A GAS SCRUBBER 22
Figure 2. 11: EXPORT PUMP 23
Figure 2. 12: Booster Pump 23
Figure 2. 13: Picture of a Closed Drain 24
Figure 2. 14: STORAGE TANKS 25
Figure 2. 15: A FLARE KNOCK_OUT 26
Figure 2. 16: CRUDE PROCESSING OIL TRAIN 26
Figure 2. 17: A typical Production Monitoring Dashboard 27
Figure 2. 18: Introduction to Drilling (Learn to Drill) Logo 28
Figure 3. 1: Overview of OML 111 30
Figure 3. 2: FST 1 Process Flow Diagram 31
Figure 3. 3: The Fire Triangle 32
Figure 3. 4: FST 3 Process Flow Diagram 34
Figure 3. 5: IGHF Process Flow Diagram 34
Figure 3. 6: Pictures of HSE safety rules 42
Figure 3. 7: Specific NEPL template for Production Monitoring 43
Figure 3. 8: Introduction to Drilling(Learn to Drill) Certificate of Completion 45

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 ABBREVIATIONS AND KEYWORDS
SIWES Students Industrial Work Experience Scheme
SBU / CSU Strategic Business and Corporate Services Units
IOGP International Association of Oil and Gas Producers
PED Petroleum Engineering Department
QAQC Quality Assurance and Quality Control
OML / OPL Oil Mining License / Oil Prospecting License
DST Drill Stem Test
FST Flow Station
HP / MP / LP High Pressure / Medium Pressure / Low Pressure
IGHF Integrated Gas Handling Unit
NPMS National Production Monitoring System
NUPRC Nigerian Upstream Petroleum Regulatory Commission
BPD / BOPD Barrels of Oil Per Day
BLPD Barrels of Liquid Per Day
IWCF International Well Control Forum
WI Well Intervention
WRFM Well, Reservoir and Facility Management
RS & AD Reservoir Studies & Asset Development
BS & W Basic Sediments & Water
MMSCF Million Metric Standard Cubic Feet
FBHP / SBHP Flowing Bottom Hole Pressure / Static Bottom Hole Pressure
FTHP / STHP Flowing Tubing Head Pressure / Static Bottom Hole Pressure
ED Executive Director
P&AM Production and Asset Management
ATT Authority to travel

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 CHAPTER ONE

INTRODUCTION
1.0 HISTORY OF SIWES
At the early stages of the development of education in Nigeria, there was a problem of the
gap between theory and practical skills of students. Therefore, there was a need to give
students the opportunity to get real work experience. The program was created to give
students experience in addition to theoretical learning. The industrial training policy was
introduced by the Federal Government of Nigeria in 1973. This project was necessary to
improve practical skills of students. SIWES has become a necessary precondition of
graduation. The program is working with such disciplines as engineering, medical science,
natural science, technology, agriculture, education, environmental, applied science. The
duration of the program can be different, for the universities it's six months, and four months
for college and polytechnics. The program is developed under the guidance of the Ministry of
Education.
This is an excellent bridge between theoretical and practical education. SIWES is working on
designing proper programs for exposing students to the industrial workplace environment. It
is all about the development of occupational competence.

1.1 OBJECTIVES OF SIWES

The objectives of SIWES program are all about strengthening future employees. Such a
program is a successful attempt to help students to understand the underlying principles of
their future work. After passing the programs, the student can concentrate on the really
necessary factors of his or her work. Referring to the feedback of students, the experience of
participating in the program has become very useful for them. Employers also note a higher
level of skills of such students.
1. To provide students with industrial skills and needed experience while the
course of study
2. To create conditions and circumstances which can be as close as possible to
the actual workflow
3. To prepare specialists who will be ready for any working situations
immediately after graduation
4. To teach students the techniques and methods of working with facilities and
equipment that may not be available within the walls of an educational institution
5. To give students the ability to try and apply the given knowledge.

1.1.2 BODIES INVOLVED IN THE MANAGEMENT OF SIWES

The bodies involved are the Federal Government and Industrial Training Fund (ITF). Other
supervising agents are: National University Commission (NUC), National Board for
Technical Education (NBTE) and National Council for Colleges of Education (NCE). The
functions of these agencies above include among others to:
⮚ Ensure adequate funding of the scheme

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 ⮚ Formulate policies and guideline for participating bodies and institutions as well as
appointing SIWES coordinators and supporting staff
⮚ Supervise students at their place of attachment, sign their logbook and IT forms

⮚ Vet and process student’s logbook and forward same to ITF Area office

⮚ Ensure payment of allowances for the students and supervisors.

⮚ Establish SIWES and accredit SIWES unit in the approved institutions

Therefore, the success of SIWES depends on the efficiency of the Ministries, ITF,
institutions, Employers of labor and the general public involved in articulation and
management of the program. Thus, the evaluation of SIWES in tertiary institutions in
meeting up with the needs for the establishment of the program is necessary.

1.2.1 BRIEF HISTORY ABOUT NNPC E&P LIMITED

NNPC was established on 1st of April 1977 as a merger of the Nigerian national oil
corporation and the federal ministry of petroleum and energy resource. NNPC by law
manages the joint venture between the Nigerian federal government and a number of foreign
multinational corporations, which include ROYAL DUTCH SHELL, AGIP, EXXON
MOBIL, TOTAL ENERGIES, CHEVRON AND TEXACO. Through collaboration with
these companies, the Nigerian government conducts petroleum exploration and production.
The NNPC tower in Abuja, is the head-quarters of NNPC and consists of four (4)
identical towers, the complex is located on Herbert Macaulay way, Central Business District
Abuja. NNPC also has zonal offices in Lagos, Kaduna, Port-Harcourt, and Warri. It has an
international office located in London, United Kingdom.
Following passage of a petroleum industry act in August 2021, the government of Nigeria
announced on July 19, 2022, that NNPC will now operate as a commercial entity without
relying on government funding and direct controls. NNPC was established as a limited
liability corporation in the hopes that a private entity will find it easier to access international
capital markets.

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 Figure 1. 1: NNPC BUILDING

1.2.2 OVERVIEW OF NNPC E&P LIMITED.

NNPC Limited is a for profit oil company in Nigeria. Formerly a government-owned
corporation, it was transformed from a corporation to a limited liability company in July
2022. NNPC Limited is the only entirely licensed operator in the country’s petroleum
industry. It partners with foreign oil companies to exploit Nigeria’s fossil fuel resources.
The NNPC group comprises the NNPC Board, the group managing director’s office, five
directorates as listed below. Each directorate is listed below, each directorate is headed by
Chiefs, while its subsidiary companies are headed by managing directors NNPC has several
subsidiaries, two partly owned subsidiaries and 16 associated companies.

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1.3 ORGANOGRAM AND RESPONSIBILITIES.
1.3.1 NNPC LIMITED ORGANOGRAM
The Nigerian National Petroleum Corporation (NNPC) is the state oil corporation of
Nigeria. As of my knowledge cutoff in September 2021, the organizational structure and
responsibilities of NNPC are as follows:

1. Board of Directors: The NNPC is overseen by a board of directors, consisting of

representatives from various sectors, including the government, the oil and gas
industry, and other relevant stakeholders. The board provides strategic direction and
oversees the corporation's activities.

2. Group Managing Director (GMD): The GMD is the highest-ranking executive in

NNPC and is responsible for the overall management and administration of the
corporation. The GMD is appointed by the President of Nigeria and reports to the
board of directors.

3. Chief Operating Officers (COOs): NNPC has several COOs, each responsible for a
specific directorate or division within the corporation. The COOs oversee and
coordinate the operations of their respective departments, ensuring efficient
functioning and achieving strategic objectives. The major COO positions include:

a. Upstream Operations: This COO is responsible for the exploration,

development, and production of oil and gas resources in Nigeria. They oversee
activities related to oil and gas exploration, field development, and production
operations.
b. Downstream Operations: This COO is responsible for the refining,
distribution, and marketing of petroleum products. They oversee activities related
to refining operations, product transportation, storage, and marketing.
c. Ventures and Business Development: This COO is responsible for
identifying and pursuing new business opportunities, both domestically and
internationally. They focus on diversifying NNPC's portfolio, forming partnerships,
and expanding the corporation's presence in the global oil and gas market.
d. Gas and Power: This COO is responsible for the development and
management of Nigeria's natural gas resources. They oversee activities related to
gas production, processing, transmission, and utilization. They also drive initiatives
to promote the use of natural gas for power generation.

4. Corporate Services: This department provides support services to the entire NNPC
organization. It includes various divisions responsible for areas such as human
resources, finance, legal, procurement, information technology, public affairs, and
corporate communications.

5. Subsidiaries: NNPC has several subsidiaries that operate in different segments of the
oil and gas industry. These subsidiaries include the Nigerian Petroleum Development

4
 Company (NPDC), which focuses on upstream exploration and production, and the
Nigerian Gas Company (NGC), which handles gas transportation and infrastructure.

Figure 1. 2: NNPC ORGANOGRAM

1.3.2 NNPC E&P LIMITED ORGANOGRAM

1.3.3 Responsibilities of Departments

1. Managing Director/Chief Executive Officer (MD/CEO): The MD/CEO is the highest-

ranking executive in NNPC E&P Limited. They are responsible for the overall
management, strategic direction, and operational performance of the company.

2. Chief Operating Officers (COOs): This COO is responsible for the exploration,
development, and production of oil and gas resources in Nigeria. They oversee
activities related to oil and gas exploration, field development, and production
operations.

3. Executive Directors (Eds): The executive directors of NNPC E&P Limited, like in
most companies, would hold senior leadership positions and have a range of
responsibilities.

4. Exploration Department: This department is responsible for identifying and

evaluating potential oil and gas reserves through seismic surveys, geological studies,
and exploration drilling. They aim to discover new hydrocarbon resources and
assess their commercial viability.

5. Development and Production Department: This department handles the planning,

development, and production operations of oil and gas fields. They work on

5
 optimizing production levels, ensuring efficient operations, and managing reservoirs
to maximize recovery.

6. Drilling and Well Services Department: This department manages drilling activities,
including the design and execution of drilling programs, well construction, and well
intervention operations. They ensure the safe and efficient drilling of wells and the
maintenance of well integrity.

7. Reservoir Engineering Department: The reservoir engineering department focuses

on analyzing reservoir properties, estimating reserves, and optimizing hydrocarbon
recovery. They use various techniques to model reservoir behavior and develop
strategies for reservoir management.

8. Health, Safety, and Environment (HSE) Department: This department is responsible

for ensuring compliance with health, safety, and environmental regulations and
promoting a safe working environment. They develop and implement HSE policies,
procedures, and training programs to protect personnel and minimize environmental
impact.

9. Geosciences Department: The geosciences department comprises geologists,

geophysicists, and other specialists who analyze subsurface data to support
exploration and production activities. They interpret seismic data, conduct geological
and geophysical studies, and provide geological models and reservoir
characterization.

10. Facilities and Engineering Department: This department is responsible for the
design, engineering, construction, and maintenance of production facilities,
pipelines, and infrastructure required for upstream operations. They ensure the
integrity and reliability of facilities and optimize their performance.

11. Finance and Commercial Department: This department handles financial

management, budgeting, and commercial activities related to NNPC E&P
Limited's operations. They oversee financial planning, accounting, contract
management, and commercial agreements with partners and customers.

12. Petroleum Engineering Department: This department is responsible for collecting

various data from different wells and making valuable decisions on the conditions of
the wells.

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 Figure 1. 3: DEPARTMENTS REPORTING TO EVP UPSTREAM

I was placed under the Production and asset management division which is
headed by an Executive Director (ED). The P&AM division is further divided
into different Assets departments such as:
❖ Oml 98
❖ Oml 111
❖ Oml 11
❖ Oml 34
❖ Oml 13
❖ Seplat jv etc

I was deployed to the Oml 98 department which is headed by a manager. The Oml
98 hierarchy is shown below:

Figure 1. 4: OML 98 HIERARCHY

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 1.4 SUMMARY OF INTERN’S ROLES/RESPONSIBILITIES AND ACTIVITIES;
As an intern at NNPC E&P Limited, your role and responsibilities may vary depending
on the specific internship program and the department you are assigned to. However, here is a
summary of the typical expectations and tasks that interns might be involved in:

1. Learning and Development: The primary purpose of an internship is to provide you

with valuable learning opportunities. You will have the chance to acquire knowledge
about the oil and gas industry, the operations of NNPC E&P Limited, and the specific
functions of the department you are working in. This may involve attending training
sessions, workshops, and orientation programs.

2. Support to Projects and Tasks: Interns often assist in various projects and tasks within
their assigned department. This can include conducting research, collecting and
analyzing data, preparing reports, and assisting in the implementation of specific
initiatives. You may work closely with your supervisor or other team members to
contribute to ongoing projects.

3. Documentation and Administrative Tasks: Interns might be responsible for organizing

and maintaining documents, files, and records. This can involve tasks such as data
entry, document filing, preparing presentations, and organizing meetings or events.
Administrative support is often a part of the intern's responsibilities.

4. Shadowing and Observing: Interns have the opportunity to shadow experienced

professionals and observe their day-to-day activities. This allows you to gain insight
into the work processes, decision-making, and collaboration within the organization.
It is a valuable learning experience to understand the industry and build professional
networks.

5. Communication and Collaboration: Interns are expected to actively participate in

team meetings, discussions, and group projects. Effective communication and
collaboration with colleagues and supervisors are essential for understanding
expectations, seeking guidance when needed, and contributing to the team's
objectives.

6. Professional Conduct and Ethics: As an intern, you are expected to maintain

professional conduct, adhere to the company's policies and ethical standards, and
respect confidentiality requirements. This includes maintaining the integrity of
information, respecting intellectual property rights, and demonstrating
professionalism in all interactions.

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1.5 SUMMARY OF WORK DONE AND DETAILED INTERN’S
ROLE/RESPONSIBILITIES AND DAILY ACTIVITIES
I participated in several activities which include;
● Field activities:
I visited the Flow station at OML 111 Oredo Field in Edo state, OML 98 Ogharefe field
in Delta State, Seplat JV(Oben gas plant) in Edo state. I was able to join their routine
activities such as pressure reading at the separators, manifolds, monitoring oil tank level,
facility management and monitoring etc.
● Office activities:
As an intern at NNPC E&P Limited, your role, responsibilities, and daily activities will
depend on the specific internship program, department, and project you are assigned to.
While the exact tasks may vary, here is a more detailed overview of the intern's role
and potential responsibilities:

1. Project Support and Research:

● Assist in ongoing projects by conducting research, gathering data, and

analyzing information.

● Support the development of project plans, timelines, and deliverables.

● Prepare reports, presentations, and documentation related to the project.

● Collaborate with team members to contribute to project discussions and

brainstorming sessions.

2. Data Analysis and Reporting:

● Collect, organize, and analyze data using appropriate tools and software.

● Assist in the preparation of reports, charts, and graphs to present data findings.

● Contribute to data quality assurance and validation processes.

3. Administrative and Documentation Tasks:

● Assist in organizing and maintaining departmental documents, records, and

files.

● Prepare and update spreadsheets, databases, and other documentation as

required.

● Support the organization and scheduling of meetings, conferences, and events.

● Assist in editing, printing, organizing field and shift forms for field engineers
alongside their ATT.

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 ● Help in managing emails, correspondence, and communication within the
department.

4. Collaborative Projects and Teamwork:

● Actively participate in team meetings, discussions, and collaborative projects.

● Contribute ideas, insights, and suggestions to enhance team productivity and

efficiency.

● Work collaboratively with team members, sharing responsibilities and

supporting each other.

● Engage in cross-functional cooperation and coordination as required.

5. Learning and Development:

● Attend training sessions, workshops, and orientation programs to

enhance industry knowledge.

● Seek opportunities to learn from experienced professionals by shadowing and

observing their work.

● Take part in knowledge-sharing activities within the department and

organization.

● Actively seek feedback from supervisors and mentors to improve skills

and performance.

6. Professional Conduct and Adaptability:

● Adhere to the company's policies, procedures, and ethical standards.

● Maintain professionalism in all interactions, both internally and externally.

● Respect confidentiality requirements and handle sensitive

information appropriately.

● Adapt to changing priorities, tasks, and deadlines as required.

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 CHAPTER TWO

THEORY BEHIND WORK DONE

2.1 Field Activities

2.1.1 Definition of an Oil Field
An oil field in petroleum engineering is referred to as a subsurface plot used for the purpose
of production petroleum. An oil field is a piece of land, which within it has reservoirs from
which fossil fuels can be trapped in a rocky stratum and extracted for economic value. An
impermeable, or sealing rock layer covers the reservoir, keeping it intact over millennia.
Because of the low permeability of earlier laid down rocks compared with the overlying more
permeable rocks; the hydrocarbon fluids generated later migrated upward. In some cases, the
hydrocarbons were prevented from rising up further by the presence of overlying
impermeable rock layers (cap rock) which then contained the hydrocarbons in so-called traps.
This gave rise to the existence of today’s oil and gas fields (reservoirs) in the porous horizons
beneath cap rocks.
Numerous wells normally have to be drilled to release the oil and gas in the reservoir
discovered by exploration to produce a significant amount of oil. In some cases, existing
wells can be utilized further for the injection of gas. Oil industry uses the term oil field with
an implied assumption of economic size. For instance, an oil field may be discovered
containing a million barrels of oil, equal to the market price of oil multiplied by its size.
Also, there are various components of an oil field which includes Drilling or workover Rig
components, Oilfield Trucks and Machinery, Pumps, Storage Tanks, Pump Containment,
Manifolds, Flair Boxes and Flair Lines, Drive Overs, Hose / Bit Houses, Catch Tanks and
other types of containment, Oilfield Lighting etc.
There are also offshore oil fields and the Safaniya field is the world's largest. Located in the
Persian Gulf off the Saudi Arabian coast, the Safaniya field is thought to hold more than 50
billion barrels of oil.

2.1.2 Flow Station

A flow station is a gathering center where primary separation/processing of the reservoir fluid
takes place. These fluids are later transported to terminals for export or to the refinery, while
the other products are either treated or flared or disposed of. A flow station is usually
designed to run automatically. It employs pneumatic instrumentation logic for control and
shut down in a safe manner. At the flow station, flow lines run from the well-head to the
manifold, then to the different separators for primary separation of the fluid into various
phases.

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 Figure 2. 1: SKETCH OF A PETROLEUM PRODUCTION SYSTEM

The reservoir fluid is most times a mixture of fluids namely;

1. Gas
2. Oil
3. Water (sometimes with basic sediments)
It is important that these fluids be handled individually according to their phases. Thus, at
the flow station, the primary separation of these mixtures takes place. Flow stations may
have different configurations, depending on the kind of reservoir, location, temperature and
pressure conditions in the geological area.

2.2 GENERAL DESCRIPTION OF A TYPICAL OIL FIELD WELLHEAD

The wellhead is mounted at the surface of an oil or gas well; it is the component at the
surface of an oil or gas well that provides the structural and pressure-containing interface for
the drilling and production equipment. The wellhead serves as an anchor point for the casing
and tubing strings. It provides a means of pressure sealing and isolation between casings at
the surface when many casing strings are used. The wellhead provides communication
access to the annulus of the well during workover operations.
The wellhead serves as a base on which the Christmas tree sits on and provides a means of
attaching a blowout preventer during drilling. The components of the wellhead include:
casing head, casing spool and hanger adapter, tubing head, tubing spool and hanger adapter,
pack offs (isolation) seals, bowl protector’s / wear bushings, test plugs, mudline suspension
systems.

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Diagrams of a well head are shown below;

Figure 2. 2: DIAGRAM OF A WELLHEAD

CHRISTMAS TREE
The Christmas tree is an assembly of valves, spools, pressure gauges, and chokes that are
fitted to the well head of a completed well. It provides flow and pressure control of fluid
through the wellhead. The Christmas tree also provides an entrance for wire lines in and out
of the well in cases of work over. The Christmas tree allows flow from the well into the
surface flow lines down into the production facility (flow station).
- Surface safety valves (SSV): The surface safety valves are present to shut-in the
well if there is an event of failure of downstream equipment, or a leak, or fire outbreak, or
any other emergency which requires a shut-in of the well. They are also referred to as Pilot
valves and are sometimes situated close to the wing valves of the Christmas tree.
- Wing valves: The wing valve serves as an outlet for hydrocarbons from the well to
the flow lines. Mounted on the tees and crossed, and are used in controlling flow from the
flow line. They are used also in initiating or stopping flow on the well.
- Choke/Bean box: This houses the choke or Bean. The choke/bean contains a
small orifice/aperture which reduces the flowrate of the fluid. Chokes may be fixed or
variable depending on its design.
Swab valve: it is an isolation valve that is required to access the wellbore for maintenance.
Used in wire line operations.

13
 - Riser: They are upward protruding part of the Christmas tree. It traps a bit of the
gas just flowing out of the well. The trapped gas now serves as fuel for the pneumatically
surface controlled devices at the wellhead.
CHOKE: The choke controls the flow rate and pressure of the well.

Figure 2. 3: A SKETCH OF A CHRISTMAS TREE

Figure 2. 3.1:PICTURE OF ME BESIDE A CHRISTMAS TREE

14
CELLAR PIT
This is a pit that surrounds the well head and the Christmas tree, its function is to contain any
spillage that may arise from producing well

Figure 2. 4: PICTURE ABOVE REPRESENTS A COVERED CELLAR PIT

15
ARRIVAL MANIFOLD
This is an inlet by which all crude oil flow-lines enters the flow station, the essence of the
manifold is for easy switching of crude oil from the well head to different separators. The
arrival manifold has ESD (Emergency Shut Down) valves attached to the headers for
automatic shutdown, in case pressure for a given header is exceeded or below it.
MANIFOLD
The individual well streams are brought into the main production facilities over a network of
gathering flowlines and manifold systems.
A gathering point made up of a combination of valves and fittings where hydrocarbon
converges and is diverted to the respective separator headers according to the flow line
pressure. The manifold contains a variable choke valve which is used to control the flow rate
and in turn control the pressure of the well stream going into the various headers. The valve
that contains the variable choke is an angle valve. It is the official “entrance” for
hydrocarbon from different wells into the production facility

Figure 2. 5: ARRIVAL MANIFOLD SHOWING VALVES

16
Figure 2. 5.1: PICTURE OF ME AT THE MANIFOLD SHOWING VALVES

CHEMICAL INJECTION SYSTEM

Defoamers, demulsifiers, and dewaxers are injected into the fluid just before it gets into the
separators and just before the gas booth in order to break emulsifying bonds in the fluid in
order to further aid separation of the component phases. These chemicals are injected
intermittently with small diameter needle valves and pumps
The Emulsion formed can be either of the following
i) Primary emulsion, which can be oil-water emulsion or water-oil emulsion.

ii) Secondary emulsion, which can be oil-water-oil emulsion or water-oil-water emulsion.

SEPARATORS
Separator is a vessel which separates fluids by means of DENSITY settling into its
constituent phases which could be oil, gasses, and water. Generally, fluid from the well is a
3-phase combination comprising gas, oil, and water. This fluid may also convey solid
particles in suspension, such as sands, corrosive products, paraffin-based, and asphalt-based
components that have been precipitated out. Hydrocarbons must be separated into their
various phases and impurities removed before they can be shipped for commercial purposes.
Separators are classified by their shape, application and number of separation phases:

17
❖ Shape: By shape, separators are either, vertical, spherical or horizontal

❖ Separation Phase: separators are either 2-phase (gas and liquid) or 3-phase (gas, oil
and water)
❖ Application: Test separator, production separator.

❖ Separators are also made use of in other hydrocarbon processing facilities apart
from the early production facility (EPF) such as; gas handling facility, refineries. In
the Early Production facility, there are other more specific separators such as: fuel
gas scrubber, knock out drum and degasser.

Figure 2. 6: Internal Feature of a test Separator

18
TYPES OF SEPARATORS
TEST SEPARATOR
The primary essence of a separator is to separate gas, water from the crude oil and at the
same time reduce the pressure at which the crude oil is coming from the well. Test separator
is similar in configuration as the other separators.
This separator has the major function of determining the “wellness” i.e., the producing
potential of the well that flows at a particular time. It is equipped with various flow metering
system necessary for measuring oil, gas, and water, for potential test, periodic production
tests, etc. it can be used to determine the nature of the well, gas oil ratio (GOR), surface
pressure, surface temperature, amount of crude produced per day, amount of gas produced
per day. Some of the meter’s present on this separator include the:

Figure 2. 7: PICTURE OF A TEST SEPARATOR

HIGH PRESSURE SEPARATOR (HP)

HP separators have the same working principle as test separators, the only difference is that
the HP is designed for crude oil from high pressure wells as pressure specified in separation
stages. The HP separator is designed to handle the bulk of the incoming production from the
high pressure well(s) and remove gas from the liquid. Crude is fed into this separator via the
HP header on the arrival manifold.

19
MEDIUM PRESSURE SEPARATOR (MP)
The MP separator has the same working principle as the test separator but the difference is
that the MP is designed for crude oil from medium pressure wells as pressure specified in
separation stages. The well stream flows in the MP separator through MP separator for
further processing. The MP separator is designed to remove free water from the oil and
remove gas from the liquid.

LOW PRESSURE SEPARATOR (LP)

LP separator has the same working principle as test separator but the only difference is that it
is designed for low pressure wells as pressure specified in separation stages. It is also
designed to remove free water from oil that is coming from the MP separator prior to sending
the oil to surge tanks or crude storage tanks.
About 65% of the existing gas from the top far end of the test separator, MP separator and HP
separator is piped to HP flare knockout vessel, while 25% of the gas is piped to fuel gas
scrubber. Except there's a gas plant in the facility, then the gas is sent to the gas plant for
processing. The gas from the LP separator is vented to the LP flare knock out vessel.

Flow analyser: for measuring quantity of liquid produced and the flow rate into/out of the
separator

Figure 2. 8: PICTURE OF A FLOW ANALYZER

Daniel orifice meter: which measures the amount of gas produced, by creating a pressure
differential through the orifice plate, that is recorded on the Barton recorder with the use of
Barton chart
Test separator typically consists of a vessel, an oil flow-measuring system with dual meters, a
flow-measuring system for gas, several sampling points for each effluent phase, and two
relief valves to protect the vessel against overpressure. Most separators are also equipped to
measure water flow rate. To provide accurate measurements, the test separator is fitted with
pneumatic regulators that maintain a constant pressure and a constant liquid level inside the
vessel by control valves on the oil and gas outlets.
The test separator is fitted with a deflector plate, coalescing plates, a foam breaker, a vortex

20
breaker, a weir plate, and a mist extractor. These components reduce the risk of carryover
(liquid in gas line) and carry under/blow by (gas in liquid line) that would affect the flow rate
measurement accuracy.

GAS BOOTH (DEGASSER)

Produced liquid from the separators is channeled to the degasser. Degassers carry out the
same function as the low-pressure separator. It extracts further traces of gas from the oil,
before it is stored. Depending on the configuration and design of a degasser, it could either be
a water degasser, or oil degasser.
The gas that is extracted from the water degasser is channeled to the Low-pressure flare
knockout drums, and the oil is stored in the storage tanks.
Gas extracted from crude degasser is channeled to the gas handling facility while the water is
channeled to the floatation cell for treatment before disposal.

Figure 2. 9: PICTURE OF A DEGASSER

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FLARE KNOCKOUT TANK
These are tanks where produced gas is channeled. The tanks dry the gas by allowing any
liquid that is with the gas to that point to settle in it, so as to allow the dried gas to be sent to
the flare knock out stack where it is being flared. We have two flares knock out tanks, they
are the LP flare knockout tank and the HP flare knock out tank. Gas from the test separator,
HP and MP separators are channeled to the HP flare knockout tank whereas the gas from the
LP separator is channeled to the LP flare knockout tank.

FUEL GAS SCRUBBER

This process plant equipment traps gas from the gas header and purifies it by removing
further traces of crude oil in it, with a mixer or extractor, then sends it to the fuel filter. The
fuel gas scrubber is designed to remove oil droplets from the incoming gas to be used as
fuel. The accumulated liquids are dumped to the closed drain sump tank. The gas is then
sent to the instrument gas filter separator, which is designed to remove aerosols from the gas
prior to sending the gas to the end users, such as gas driven generators and cooking.

Figure 2. 10: A GAS SCRUBBER

22
PUMPS:
In the transfer of crude from the flow station for export or to the refineries, pumps are used.
These pumps include the booster pump which is a centrifugal volume pump that pumps the
crude out of the tanks and the Export pumps which further pressurizes the crude to pump it
over a long distance (several thousand kilometers). The export pump is usually a
reciprocating pressure pump. Booster Pumps: These pumps collect crude oil from the crude
oil storage tanks and boost the pressure on the export line for the major export pump to pick
up on an adequate line pressure.
In a simplified sense, it describes below:
(a) Booster Pumps: These pumps collect crude oil from the crude oil storage tanks and
boost the pressure on the export line for the major export pump to pick up on an adequate line
pressure.
(b) Export Pumps: These pumps depend on the pressure built by the booster pump to
suck and discharge crude oil for export.
(c) Produced Water Transfer Pumps: These pumps suck water from the storage tanks and
send it into the skimmer.

Figure 2. 11: EXPORT PUMP Figure 2.12: Booster Pump

23
WATER DEGASSER
This is the equipment that receives produced water from the separators and extracts further
traces of gas and oil from the water. The produced water dumped by the HP, MP, LP and test
separators is piped to the water degasser. Each of the four separators (HP, MP, Test, LP) and
water degasser has a transparent type level gauge for monitoring oil/water interface inside the
main section of the vessel before the weir plate. These separators are cylindrical in shape and
are made of carbon steel materials, their thickness varies with depth. The degasser is also
designed to remove large oil droplets from the water by feeding oil water through the three
sets of coalesce plate packs. The water discharged from the water degasser is then sent to the
floatation cell or corrugated plate interceptor (CPI) for final treatment. The accumulated oil is
pumped to the closed drain sump tank. Any excess gas which breaks out from the water,
while inside the water degasser vessel is vented to the LP flare knockout tank, and the water
is sent to the skimmer pit.
FLARE SCRUBBERS:
The HP Flare Scrubber and LP Flare Scrubber are designed to scrub any Liquids from the gas
stream that is being vented prior to flaring.
CLOSED DRAIN
The Closed Drain Sump Tank and Associated Diaphragm Pumps are designed to accumulate
the liquid from the closed drain header and then pump this liquid back to the LP separator for
reprocessing. This pump must be adjusted to discharge oil from the drain tank into the LP
separator and overcome the pressure inside the LP separator. The drain tank basically
operates at atmospheric pressure and any pressure gasses which accumulate inside the vessel
are vented to the atmosphere through a vent type flare arrestor. Pump exhaust gas is piped
into the drain tank so that flammable gasses are not present around the drain tank. The tank
will be placed in a cement pit approximately 1 meter below grade to facilitate liquids drain
header draining into this vessel.

FIGURE 2.13: PICTURE OF A CLOSED DRAIN

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CRUDE OIL STORAGE TANK
After separation, the crude is allowed to settle and kept here until when it is to be exported.
These tanks allow gas liberation while limiting pressure loss through evaporation. The tank
has the following accessories;
*Production or Inlet pipe: generally fixed at the bottom of the tank and internally extended
with a perforated pipe rising in a cage. This device acts as a separator, which permits the
liberation of gas towards top and helps to avoid the agitation of liquid hence promotes the
draining.
*Discharge or export pipe: this is also fixed at the body of the tank at a certain height,
perforated and extended in the tank. It makes it possible to discharge crude oil at the top.

*Drainage pipe: This is used to drain water from the tank.

*Overflow pipe: These pipes are here for safety purposes, if a tank is filled, and production is
still ongoing, these pipes all crude to enter another tank

*Man-hole: all storage tanks are equipped with one or two man-holes to be used as an
access into the tanks to carry out repairs or cleaning. All tanks must also be free of gas
before any work is carried out in order to avoid explosion due to gas and air. Therefore, to
degas the tank, vapor must be injected and then an explorimeter is used to verify if it has
been degassed.
*Level controllers: these are liquid level indicators that give direct reading of the level of the
liquid.

FIGURE 2. 14: STORAGE TANK

25
METERING UNIT
Crude being exported passes through the metering unit, to get the time and cumulative
reading of crude being exported. The metering unit records in barrels per day. The meter is
clocked off daily to get cumulative daily shipment.
FLARE KNOCK-OUT STACK
This is a point where all the gas after being filtered from water and oil in the flare knock-out
tanks is flared.

FIGURE 2. 15: A FLARE KNOCK_OUT

CRUDE OIL PROCESSING TRAIN

FIGURE 2. 16: CRUDE PROCESSING OIL TRAIN

26
2.2 OFFICE ACTIVITIES
Production Monitoring
The National Production Monitoring System (NPMS) has finally come on stream.
The objective of this project is basically to provide an online platform to accurately monitor
national crude oil production and exports, through the provision of a system for direct and
independent acquisition of production data from oil and gas facilities in Nigeria to ensure
timely and accurate reporting of production figures and export data. It replaces the current
paper-based report. NPMS ensures ready production reporting to FIRS, NEITI and other
Agencies.
NPMS as envisaged will empower the NUPRC to better determine the royalty payable
and issue demand notice on companies. In addition, the nation will be able to better
predict the performance of oil and gas reservoirs and therefore better production
forecasting.

Figure 2. 17: A typical Production Monitoring Dashboard

The above objectives and gains are achieved essentially by implementing electronic data
transmission at Export Terminals (onshore and offshore) by NUPRC personnel, as well as at
the offices of the Operators. This data is then stored in a robust, secure and centralized
database to ensure uniformity, consistency and quality. The system includes facilities for the
NUPRC to exercise surveillance, perform production monitoring, and to be able to utilize the
production data for analysis and forecasting. Access to data is also available to authorized
NUPRC personnel, operator’s other relevant stakeholders. The imperatives of the NPMS
scheme are viewed against the backdrop of persistent calls for a more efficient, accurate and
robust surveillance of the nation’s oil production and export capabilities. The underlying
strength of the NPMS is to further ensure NUPRC’s ability to accurately determine the exact
revenue accruing to Nigeria from the oil and gas sector. A key benefit is that it also provides

27
modern and reliable technology for fiscalization of crude.
All Oil Producing Companies are to submit production data through the portal
forthwith to enable the Commission effect a comprehensive real time reporting of the
nation’s daily production status to Government. Please note that failure to comply is
contrary to Section 52 of the Petroleum (Drilling and Production) Regulations, 1969 as
amended and will attract necessary sanctions from NUPRC.

Introduction to Drilling (Learn to Drill) course

FIGURE 2. 18: LEARN TO DRILL LOGO

LTD launched a free course on Drilling in 2015. Learn to Drill is an online training platform
that offers courses and simulations in well control, drilling operations, and health and safety
training for the oil and gas industry. Their courses are designed to be engaging, interactive,
and accessible to all levels of experience, from non-technical individuals to experienced
professionals.

Some of the topics covered in their courses include:

- Well Control: understanding the principles of well control, kick detection, and prevention
- Drilling Operations: introduction to drilling equipment, mud circulation systems, and drilling safety
- Health and Safety: fire safety, emergency response, and occupational health
- Well Servicing: well intervention pressure control, wireline operations, and coiled tubing

Course Content
The Learn to Drill course covers a range of topics, including:

1. Well Control Fundamentals:

- Well control principles
- Kick detection and prevention

28
 - Well control equipment
2. Drilling Operations:
- Drilling equipment and procedures
- Mud circulation systems
- Drilling safety
3. Health and Safety:
- Fire safety and emergency response
- Occupational health and hygiene
- Hazard identification and risk assessment
4. Well Servicing:
- Well intervention pressure control
- Wireline operations
- Coiled tubing operations
5. Enhanced Oil Recovery (EOR):
- EOR techniques
- Well stimulation
- Artificial lift systems

Conclusion:
At the end of each module there is a knowledge check which candidate must successfully
complete before moving on to the final exam. If a pass mark of 80% or more is achieved in
the final exam candidates will be able to access their online certificate.
Overall, "Learn to Drill" provides comprehensive and engaging training for oil and gas
professionals, with a focus on well control, drilling operations, and health and safety.

29
 CHAPTER THREE

ACTUAL WORK DONE / EXPERIENCE GAINED

3.1 OML 111 and 98 Flowstation Field visit
Fields in Nigeria were formally called OML (Oil Mining License), but after the PIA
(Petroleum Industrial Act) are now intended to be called PML (Petroleum Mining License).
Regardless, I visited the flow stations at OML 111 (OREDO field) in Edo State, and OML 98
(Ogharefe) in Delta state, Nigeria. The flowstations at OML 98 and OML 111 are quite
similar. The OML 98 asset has just 1 flowstation while the OML111 asset has three flow
stations and an integrated gas handling facility (IGHF) which liquefies and separates gas into
its various components. I will focus more on Oml 111.
I was opportune to see the schematics and mechanics by which fluids move through the
equipment for effective production. The flow stations are numbered as FST-1, FST-2,
FST-3 and Integrated Gas Handling Facility (IGHF). FST-2 was non-functional at the time
of my visit as it was under development while FST-1 and 3 were used to produce,
transport and separate the phases in the oil before it is transported to the Forcados Oil
Terminal for export.

Figure 3.1: Overview of OML 111

I was shown around the facility, various components and equipment, how they
function and what they function to do.

30
3.1.1 FST-1 PROCESS FLOW

This flow station was designed to process 15 MMSCF of gas and 10,000 BPD. The fluid
(crude) flows from the well head through the flow lines where it enters the manifold. The
manifold is a combination of different headers; the MP (medium pressure) header, Test
header and flexibility / HP (high pressure) header.
In the manifold, there are ball valves which control the flow from the wellhead pass through
into the manifold, from the manifold the fluid moves to the two (2) separators which are the
test separator and MP separator. In the test separator the water stays to the bottom because it
is denser than oil, while the gas stays at the top of the separator.

Figure 3.2: FST 1 Process Flow Diagram

31
From the test separator the oil and water move out through the outlet flow lines carrying the
oil and gas to the Gas boot or degasser, in this vessel it separates any particle of gas that may
have followed the oil and water and take the gas to the Knockout Drum (which scrubs out gas
from the liquid that may have gone along side with it and takes it to flare). The oil and water
in the Gas boot moves to the surge tank, here in the surge tank it allows it to settle down,
where the water is being drained and sent to the savers pit and the oil is sent to the storage
tank. The gas in the test separator flows out through the mix extractor and flows in the gas
flow lines which when going to the IGHF there is a Fuel Gas Scrubber (FGS) that catches
any particles of crude in the gas. The FGS is used as utility in the flow station, also to power
generators, use for cooking gas and some sent down to Knockout Drum for flare.
I was also taken to safety department and given some safety precautions like the three (3)
golden rule of the field which are;
C – Compliance to rules and regulations
I – Intervene in emergency situations when necessary
R – Respect to everyone.
In case of emergency, everyone moves out for safety and gathers at the muster point on
hearing the sound of the alarm. There are three elements that results in fire when they are
present in adequate quantities:
1) Fuel
2) Oxygen
3) Heat

Figure 3.3: The Fire Triangle

Steps in handling a fire extinguisher abbreviated as PASS

P – Pull the pin off
A – Aim at the base
S – Squeeze the lever
S – Sweep at the fire

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3.1.2 FST-3 PROCESS FLOW

The facility is built to produce 100 MMSCF of gas, 10,000 BPD for oil and 2000 BPD.. The
flow station has six (6) wells and two strings attached to each of the wells. The flow starts
from the well head through the battery limit and then the fluid flows into the inlet of the sand
separator. The sand separator helps to remove as much debris as it can from the
hydrocarbons. It then flows into the inline heater.
THE INLINE HEATER: The Inline heater has a heating element in it known as the
Thyroster. It converts electrical energy into heat energy. When the heat is generated, It
passes through a liquid (Mono-ethylene glycol) which then heats the liquid (Convection) and
the liquid in turn heats the pipe in the heater through conduction. The heated pipe then heats
up the hydrocarbon. The liquid compartment of the inline heater is coated with aluminum to
retain the heat.
The major function of the Inline heater is to prevent hydrate formation. The other
functions are:
-To break down bonds between the oil and the gas.
-To control flow rate. The Inline heater has an adjustable choke which can be used to control
the flow rate.
From the Inline heater, the hydrocarbons flow into the inlet manifold. From there through
headers to the separators. At FST-3, there are 4 headers:
-The XHP header (Extra high pressure)
-The HP header
-The LP header
-The Test header
The hydrocarbons usually come from extra high pressure wells (about 800 psi) and so pass
through the XHP header into the XHP separator. The XHP separator is a vertical 2 phase
separator that separates hydrocarbons into gas and Liquid.
THE GAS (From the XHP separator)- After separation, the gas flows through the gas outlet
to the XHP media filter. The media filter helps to remove any moisture in the gas. From the
media filter, the gas moves to the compressor through the compressor header. It then flows to
the TEG unit (Tri-ethylene glycol) and then to the export line.
THE LIQUID (From the XHP separator)- The liquid from the XHP separator moves to the
HP separator. The HP separator is a horizontal 3 phase separator. The gas from here goes to
the compressor. The oil goes to the LP separator. This separator is also a 3 phase separator.
The oil from the LP separator goes to the CSU (Condensate stabilization unit) and then to the
surge vessel.
WATER- The water from the HP separator flows to the water skimmer. The water skimmer
removes any oil left in the water and this oil passes an outlet to the closed drain and from the
closed drain it goes back to the LP separator. From the water skimmer, the water moves to
the floatation cell and from the cell to the cellar pit. The water from the LP separator goes to
the water skimmer.
The gas from the LP separator goes to the VRU (Vapor recovery unit) and then to the flare.

33
 Figure 3.4: FST 3 Process Flow Diagram

3.1.3 INTEGRATED GAS HANDLING FACILITY [IGHF]

All gasses gotten from flow stations sent down to IGHF where they meet at the battery limit,
then move to scrubber then to the compressor to increase its pressure, then from the
compressor, the gas goes into the coolers then to the discharge filter, after which the gas
moves to TEG (this is the first stage of dehydration and it absorbs liquid content), then to the
inlet separator next to coalescing filter after which the gas moves to mol sieve unit

Figure 3.5: IGHF Process Flow Diagram

The gas moves to the gas filter which has a two-outlet product exchangers and inlet gas ex-
changer, the gas from the product exchanger moves into the product storage tank. Gas from
the inlet gas exchanger moves into three (3) different vessels; Expander, Dim utilizer and
cold separator. The fractional units of IGHF are; De-Methanizer, De-Ethanizer, De
Propanizer, De-Butanizer.

During my OML 111 field visit;

1. I helped in the export process for the oil. I put on the export pump which was
connected to Tank B and C and then I monitored the oil suction pressure level. The

34
 suction pressure must not be more than 600 psi and the discharge pressure must not be
more than 60 psi.
2. I did lab experiments on the crude samples gotten from the LACT unit. I took readings
from the lact unit( Barrel and totalizer) and the temperature, density, BS&W.
3. I did an HSE investigation at the facility. Unsafe acts and conditions. I went round the
facility, taking notes of unsafe acts and conditions.
4. I was taught the radio alphabet and given a radio for communications when I’m at the
flowstation field.
5. I took readings from the HMI at the gas plant.
6. I helped to convert the FST-2 to manual from automatic when maintenance was to be
done at the control room.

RADIO ALPHABETS

A- Alpha N- November
B- Bravo O- Oscar
C- Charlie P- Papa
D- Delta Q- Quebec
E- Echo R- Rome
F- Foxtrot S- Sierra
G- Golf T- Tango
H- Hotel U- Umbrella
I- India V- Victor
J-Juliet W- Whiskey
K- Kilo X- X-ray
L- Lima Y- Yankee
M- Mike Z- Zulu

35
3.2 SEPLAT JV Field Visit

At SEPLAT NEPL JV, there are 4 OMLs (oil mining lease). OML 4, OML 38, OML 53.
OML 4 is the Oben gas plant facility in Edo state.
OML 41 is the Amukpe flow station in Sapele, Delta state.
OML 38 is the Sapele west flow station in Sapele, Delta state.
OML 53 located at Imo state.

I was assigned to NEPL SEPLAT JV, OML 4 (Oben gas plant).

SEPLAT bought some parts of SHELL in 2010 which includes the OBEN gas plant.
The OBEN gas plant as at the time SHELL still owned it had only 2 modules. After
SEPLAT bought it from SHELL, they added 5 trains. So now, there are 2 gas plants at the
OBEN facility.
The 1st gas plant which is the modules have a total of 90 MMSCFD., 45MMSCF each. The
2nd gas plant (the trains) has a total of 375 MMSCF i.e 75MMSCF each. In total, the Oben
gas plant has a design of 465 MMSCF.
The Oben gas plant has 4 stations
1. The gas plant
2. The AG (Associated gas) station
3. The flowstation
4. The booster station

3.2.1 THE BOOSTER STATION

At the booster station, we have the control panel where the booster section is controlled and
monitored. The HMI (Human Machine Interface) is the body of the control panel and on the
HMI, the MCP(Master Control Panel) is installed. There are sensors at the booster station
that send signals to the MCP such as flare sensors, fire sensors and gas sensors.
There are 2 kinds of gas that comes to the booster section. The AG (associated gas) and
NAG(non-associated gas).

Gas from the gas wells(Non associated gas)

The hydrocarbon (majorly gas) comes from the well to the inlet manifold. The gas comes at
a pressure of approximately 90 bar. The gas plant works with a pressure of above 120 bar,
hence the reason for the booster station.
From the inlet manifold, the gas moves to the inlet separator. This is a 2 phase separator
which separates the gas from the liquid. The liquid (condensate) is sent to the flow station
and pumped with the crude oil. The gas moves to the Hp compressor.
There are 3 Hp compressors and 1 Mp compressor at the booster station.
The Hp compressor type is Ariel and has a caterpillar engine. The engine is a G3516 series.
i.e it is a G35 series and has 16 cylinders.
The Hp compressor:
When the gas gets to the compressor, it moves firstly into the suction scrubber. The function
of the scrubber is to scrub out any liquid still present in the gas. Liquid scrubbed out of the

36
gas moves through the liquid outlet and goes to the flowstation. The gas moves through the
gas outlet into the pulsation bottle. This bottle helps to reduce the vibration by absorbing
pressure fluctuations using the mass-spring damping mechanism. From the pulsation bottle,
it then moves into the compressor bottle. It is a single stage-double acting-reciprocating
compressor. The compressor then compresses the gas to about 135bar. The gas then moves
through the outlet into the discharge bottle. From the discharge bottle, it moves to the fan
cooler. The fan cooler cools down the temperature of the gas. After the gas has been cooled
to a certain temperature, it is then sent to the trains.

Gas from the AG station

The gas from the AG station is an associated gas because it is obtained from oil wells. It is
sent from the flowstation after the hydrocarbon from the wells have been separated to the
AG station and sent from the AG station to the booster station. This gas is a medium
pressure well at 75 bar. From the AG station, the gas is sent to the Mp compressor at the
booster station.
The Mp compressor is an Ariel type compressor and has a caterpillar engine design. It is a
G3606 series. G36 series and has 6 cylinders.
Every process that happens in the Hp compressor, happens in the Mp compressor.
After the gas is compressed and cooled, it is sent to the trains.

Factors that can trigger the shut down of the compressor:

1. Shortage of oil (lubricant) in the engine.
2. High liquid level. The compressors are not designed to compress liquids. So there’s a
certain level of liquid the compressor can take. When the liquid gets to that level, the
compressors automatically shutdown.
3. Flare, gas detectors. There are detectors installed around the compressors to detect gas
leakages or fire etc. once a leakage is detected, it sends a signal and if not immediately
attended to, it would automatically shutdown.
4. Vibrations. High vibrations can cause bolts to loosen which could cause damage. There’s
a vibration sensor installed on the compressors to detect these vibrations.

3.2.2 THE GAS PLANT

The gas wells are grouped according to their pressure. The XXHP (extra extra high
pressure) wells are grouped together and the hydrocarbon is sent to the XXHP separator.
The HP (High pressure) gas wells are sent to the booster station to boost their pressure
before they are sent to the XHP header (Extra high pressure). The wells from the AG station
are also sent to the booster station, boosted and sent to the XHP header. The XHP wells are
grouped together and the gas is sent to the XHP header.
From the XHP header, the gas flows into the inlet separator. There are two inlet separators.
This separator is a 2 phase vertical separator. Separates into liquid and gas. The gas flows
into the production header and the liquid flows to the liquid inlet separator.
The 5 trains take feed gas from the production header. These trains work independently.

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Taking 1 train as a case study;
NB: all trains work the same way.
From the production header, the gas flows to the gas-gas exchanger at the trains.
At the gas-gas exchanger;
It is a tube and shell exchanger. At the exchanger vessel, incoming gas exchanges heat with
outgoing gas. There is an inlet in the gas-gas exchanger that allows for the injection of
glycol. Glycol has a strong affinity for water and so it is injected at this stage to absorb any
water content present with the gas.
The gas enters into the tubes(incoming) and heats up the tube which in turn heats up the gas
in the shell(outgoing). The outgoing gas is a very cold gas returning from the LT separator.
After there has been an exchange of heat and the outgoing gas has been heated up, it flows
into the sales gas heater where it will be further heated up and then flows to the sales line.
The incoming gas which has now been cooled flows into the LT separator through a JT
valve (Joe Thompson valve). This valve uses pressure drop to drop the temperature of the
gas.
The LT separator is a horizontal 3 phase separator working with a temperature of about
-5℃. It separates the fluid into 3 phases; gas, condensate and rich glycol (glycol that has
absorbed water). Water has a freezing point of 0℃ but would not freeze because it has been
absorbed by glycol. Glycol (DEG) has a freezing point of -6.5℃.
The gas
The gas flows through the outlet back into the gas-gas exchanger as cold gas and exchanges
heat with the incoming hot gas and gets heated up. The gas then flows into the sales heater
to increase the temperature of the gas to about 35℃ and then flows to the sales line for
export.
The condensate
The condensate flows through an outlet into the LT coalescer. The LT coalescer has 2
elements; 1. Infiltrating element, 2. Coalescing element. Because of the low temperature,
there might be some emulsions present in the condensate. The coalescing element helps to
break down these emulsions and is then filtered.
The coalescer separates out any rich glycol left and this flows through an outlet to the DEG
(Di-ethylene glycol) unit.
The condensate then flows through an outlet to the LTS condensate heater (Low temperature
separator). This helps to heat up the condensate to help reduce the duty of the condensate
stabilizer. The condensate flows from the heater to the condensate header.
The rich glycol
The separated glycol (rich glycol) flows through an outlet to the DEG unit.

Liquid
Liquid from the inlet separators and XXHP separator goes into the inlet liquid separator.
There are 2 inlet liquid separators. It is a horizontal 3 phase separator (gas, condensate and
water).
The gas that has been separated flows through an outlet back to the LTS(Low temperature
separator) and the water is sent to the condensate line. This is done because there is no water
treatment plant at the Oben plant. The mixture of the condensate and water is sent to the

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flowstation after stabilization and is then pumped with the crude oil, separated again and
then sent to the Amukpe water treatment facility.
The condensate goes to the condensate header and flows to the condensate stabilizer.

The stabilizer
There are 2 condensate stabilizers which have a capacity of 10 barrels each.
The condensate from the condensate header flows into the condensate stab (cool
condensate). Hot gasses (lighter ends) from the reboiler exchange heat with the cool
condensate in the stabilizer. This heats up the condensate and lighter ends (gasses like
methane, propane, ethane) moves to the top of the stabilizer and flows through an outlet to
the primary fuel gas separator.
The heavier ends flow into the reboiler and are then heated up to a certain temperature. The
lighter end (hot gas) flows back to the condensate stab to heat up the condensate and get
cooled down (heat exchange). The heavier ends in the reboiler then flows into the
condensate cooler. After being cooled down, the condensate pump then pumps the
condensate to the flowstation. The condensate is separated again at the flowstation and the
waste (water) is then sent to the Amukpe water treatment facility.

3.2.3 DI-ETHYLENE GLYCOL (DEG) UNIT

At the DEG unit, the rich glycol is heated up at a temperature above the boiling point of
water but below the boiling point of glycol. The water then evaporates off and the lean
glycol is then conserved and reused later.
Boiling point of Water: 100℃
Boiling point of Glycol (DEG): 244℃

3.2.4 THE WELLHEAD

The christmas tree sits on the top of the wellhead.
A wellhead is the equipment at the surface of an oil or gas well that controls the flow of
fluids from the well. It is the primary interface between the wellbore and the production
facilities.
A typical wellhead consists of:
1. Casing head: Connects the well casing to the wellhead.
2. Tubing head: Connects the production tubing to the wellhead.
3. Christmas tree: An assembly of valves and fittings that control the flow of fluids.
4. Valves: Control the flow of fluids, including gate valves, choke valves, and check valves.
5. Pressure gauges: Monitor the pressure of fluids at the wellhead.
6. Flow meters: Measure the flow rate of fluids.
7. Choke: Adjusts and regulates the flow rate, temperature and pressure.
For oil wells(with liquid,water and gas), the gas helps in lifting the oil to the wellbore.
Process of opening:
Open flowline valve
Open the lower master valve
Open the upper master valve
Open the wing valve

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Process of shutdown:
Close the wing valve
Close the upper master valve
Close the lower master valve
Close the flowline valve

The CCU (central control unit):

High high pilot- It is set at a particular pressure to withstand backpressure. If there’s a
shutdown at the station, there will be a backpressure at the wellhead. So the High high pilot
on the christmas tree shuts down when the pressure exceeds the set pressure.
Low low pilot- It is set to a particular pressure. If well pressure is declining, it trips the
CCU. Which then pressurizes the downhole so as to increase the pressure.

During my SEPLAT JV field visit;

1. I assisted the booster station engineers to stabilize the MCP (Master Control Panel),
when it was sending a false fire alarm. The alarm was because the fire sensors were
picking the flare from afar. We changed the position of the sensors and stabilized the
MCP.
2. I assisted the control room operators and the field engineers to stabilize the gas plant
when there was a trip.
3. I engaged in bleeding of the compressor when there was a notification at the control
room.
Bleeding a line is letting the fluid run out enough so that any trapped air bubbles are pushed
out, but you are not completely emptying the line.
4. I assisted the engineers at the burner to fix one of the burners (Burner A) ang get it
running.
The burner is used to heat up the liquid used in the plant for heating. The liquid used at
SEPLAT is Dowtherm Q.

5. I took daily pressure and temperature readings from the inlet manifold.

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3.3 HSE (HEALTH, SAFETY AND ENVIRONMENT)

Safety and health management is one of the vital constituents of Oil and Gas industry activities because
most of the operational conditions, chemicals and end products (hydrocarbons and other compounds)
associated with Oil and Gas production are well-known to pose serious safety and health threats to the
workers. There is the need for an effective occupational safety and health management system that
integrates safety and health concerns into a daily routine. People working in Oil and Gas industry are
exposed to various risk factors.

Workers in Oil and Gas industry are generally susceptible to the following agents which lead to various
health hazards:

✔ Chemical hazards (toxic, corrosive, carcinogens, asphyxiates, irritant and sensitizing substances);

✔ Physical hazards (noise, vibration, radiations, extreme temperature);

✔ Biological hazards (virus, parasites and bacteria).

The following are NEPL’s 12 Life Saving Rules.

1. Work with a valid Work Permit when required.

2. Conduct Gas Tests when required.

3. Verify isolation before work begins and use the specified life protecting equipment.

4. Obtain authorization before entering a confined space.

5. Obtain authorization before overriding or disabling safety critical equipment.

6. Protect yourself against a fall when working at height.

7. Do not work under a suspended load.

8. Do not smoke outside designated smoking areas.

9. No alcohol or drugs while working or driving.

10. While driving, do not use your phone and do not exceed speed limits.

11. Wear your seat belt.

12. Follow prescribed journey management plan

NNPC Exploration and Production Limited (NEPL), preaches safety in all its activities and that is why it has
a department that is solely responsible for the enforcement of HSE industry standards called QHSED.

41
QHSED means: Quality, Health, Safety and Environment Department. The QHSE department traditionally
organizes Periodic Safety Awareness Campaigns, statutory Environmental Impact Assessment (EIA), Post
Impact Assessment (PIA), etc. The Health and Safety of the employees is top priority, therefore, policies
with respect to working conditions, regardless the location, are aimed at achieving maximal protection of
safety and health with zero accidents. There are many policies that have been put in place by NPDC which
include: Occupational Health and Safety policy, Environmental policy, Journey Management policy, etc.

Figure 3. 6: Pictures of HSE safety rules

42
3.4 OFFICE ACTIVITIES

I attended various lectures and knowledge sessions, well conduits of NEPL updating using
OFM data, production monitoring and updating, and I undertook Level 1 of a free online
course organized for both students and trained engineers by the IWCF. These activities are
explained in details below

3.4.1 Production Monitoring

I also participated in the daily routine of updating and monitoring production data
for analysis by the company in order to optimize production and report to regulatory
bodies on the status of production regularly.

Figure 3. 7: Specific NEPL template for Production Monitoring

Data updated and available on the template includes;

✔ Serial Number - Numbers in ascending order starting from 1 to know the number of rows.

✔ Managing Company - Company operating and managing that particular facility.

✔ Terrain - Land, Swamp or Offshore.

✔ Concession - Block designated by NUPRC to manage the company.

✔ Field - Name designated to a particular field.

43
✔ Well Name - Name designated too particular well.

✔ String Name - Serial, Lima or Tango strings.

✔ Reservoir - Name designated to a particular reservoir.

✔ Well Status - Flowing or Shut-In.

✔ Last Date of Production Prior to Shut-In.

✔ Fluid Type - Oil, Gas or Condensate Gas.

✔ Gross Rate - BLPD (volume of liquid) obtained from that string.

✔ BS & W - Water Cut produced from string.

✔ Net Oil - BOPD gotten from that string.

✔ Gas Rate - Volume of Gas produced from that string in MMSCF.

✔ GOR - Gas to Oil ratio produced in SCF / BBL.

✔ FBHP - Bottom Hole Pressure when well is flowing.

✔ Cumulative Production through the Year.

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3.4.2 Introduction to Drilling (Learn to Drill) Course
I undertook an online course on the fundamentals of Drilling. A Programme organized by
the IADC and I was awarded a certificate upon completion.

Figure 3. 8: Learn To Drill Certificate of Completion

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3.5 Experience Gained

During the duration of the Programme, I learned how to communicate well on the
field, the importance of networking, how to interpret and fix errors in the system,
management of resources and/or people and various safety tips to ensure optimum health
and performance on the field.

I was able to complete a basic drilling course.

I was able to learn some of the field operations in the gas plant and flowstation.

I was also able to relate a number of abstract academic knowledge and understand
their importance and application in petroleum engineering.

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 CHAPTER FOUR

CONCLUSION AND RECOMMENDATIONS

4.1 Conclusion
As an intern at NEPL, I was fortunate to have the opportunity to work on a wide range of
projects and tasks that allowed me to gain valuable hands-on experiences in my field. My
experience was amazing, and during my time, I was exposed to many ‘real life’ situations and
challenges encountered in the Oil and Gas Industry.
My Supervisors and other staff provided me with mentorship and encouragement, and I
always felt comfortable asking questions and seeking advice. I learnt a great deal from their
expertise and experience, and I am grateful to have had the opportunity to work with such a
talented and supportive team.
I had a tremendous experience working under NEPL. Within the duration of six months, I
was able to visit the flow station and gas plant. I learnt a lot, which will help me for now and
the future. I learnt about the operations going on at the various flow stations and how most of
the separating plants work and also how to carry out daily production reading and
calculations.
I was able to acquire relevant and valuable skills especially in communication and
presentation
I was able to understand the basic lifesaving rules drawn out by NEPL in respect to the oil
and gas industry
I was able to know the importance of being a team player and not choosing to always
work by oneself.

This Industrial Training has provided me with basic practical and theoretical knowledge that I
may not have gotten from the lecture room. It has given me a feel of what it would be like
after graduation, when I become part of the workforce in the industry.

4.2 Recommendations
The following are my recommendations during the 6 months SIWES program:
i. I would recommend that the University should help students to secure internship
positions according to their respective disciplines at the University through giving student’s
recommendations in order to avoid the stress, headache and rejection gotten by students in
search of internship placements.
ii. I recommend that proper orientation should be done for incoming students so as to
familiarize them with the existing procedures.
iii. I recommend that students should be given more practical work in schools, by
developing and equipping the laboratories in our institutions so that the experience does not
seem entirely new to them.
iv. Tertiary institutions should encourage scholars to write relevant textbooks that
students can fall on when they are going for industrial training exercise.
v. Organizations that accept students for the SIWES program should provide a
conducive and safe environment for students, if available then a development of a
structured learning scheme for students is advised.

47
 REFERENCES
IWCF modules. (2023). https://www.iwcf.org/programmes/level-1/
Akerejola.O. (2018). Information and guidelines for student industrial work
experience scheme (SIWES)
Pictures from http/www.google.com
Lecture note taught by Mr Baka, Mr Ba, Miss Sharon, Mr Abdul
Field experience taught by Mr Peter, Mr Eddie, Mr Precious, Mr Eghosa, Mr
Emeka.
SWEP Guide. (2021). University of Port Harcourt.
NNPC Library. (2023). https://nnpcgroup.com/
BMS control articles. (2023). What is a Flow Station?
https://bmscontrols.co.uk/blog/what-is-a-flow-station/
Neftegazru. (2021). What is an Oil field? https://neftegazru.com/tech-library/geology-
of- minerals/664208-field/

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