OTC 4542

Hondo Field Development and Operations

by R E . Olson, D.R. Olsen, J.D. Rullman, and F.G.Vasser Ill, Exxon Co. U.S.A.

I Copyr~ght1983 Offshore Technology Conference

This paper was presented at the 15th Annual OTC in Houston. Texas, May 2-5. 1983. The material is subject to correction by the author. Permission to
copy IS restricted to an abstract of not more than 300 words.

used f o r gas l i f t and t h e remaining gas i s r e i n -

jected. Gas s a l e s t o onshore t r e a t i n g f a c i l l t i e s
On A p r i l 1, 1981, Exxon i n i t i a t e d p r o d u c t i o n w i l l b e g i n i n l a t e 1983.
from t h e Hondo F l e l d i n t h e Santa Ynez U n i t t h r o u g h
the i n t e r d e p e n d e n t o p e r a t i o n o f t h e Hondo P l a t f o r m , Produced 011, gas, and w a t e r a r e processed on
an O f f s h o r e S t o r a g e and T r e a t i n g v e s s e l (OS&T), and t h e OS&T, whlch 1 s a c o n v e r t e d 50K dead w e i g h t t o n
a S i n g l e Anchor Leg M o o r i n g (SALM). The i n i t i a l tanker. P r m c i p a l OS&T p r o c e s s a c t l v l t l e s m c l u d e
d e v e l o p m e n t o f Hondo p r e s e n t e d E x x o n w l t h many o i l - w a t e r s e p a r a t l o n , c r u d e s t a b l l l z a t l o n , f u e l gas
p h y s i c a l and r e g u l a t o r y c h a l l e n g e s which have been treating, a n d s u l f u r r e c o v e r y . S o u r c r u d e 011
s a t l s f i e d t h r o u g h innovative f a c i l l t i e s d e s i g n and emulslon contalnlng approxlmately e l g h t percent
successful f i e l d operatlons. T h i s paper w i l l f o c u s w a t e r a n d 1 0 0 p a r t s p e r m l l l l o n (ppm) hydrogen
on Exxon's e x p e r i e n c e w i t h t h e Hondo F l e l d d u r i n g s u l f l d e (H S) 1 s t r e a t e d I n dehydration and sweet-
the f l r s t 21 months o f o p e r a t i o n and w i l l h i g h l i g h t enlng f a c % l l t l e s t o a cargo s p e c l f l c a t l o n o f
areas o f o p e r a t i o n w h i c h distinguish Hondo f r o m t h r e e p e r c e n t w a t e r and 1 0 ppm H S. The OS&T 1 s
other o f f s h o r e developments. c a p a b l e o f s t o r l n g 210 K b a r r e l s 6 f t r e a t e d crude,

I Introduction
whlch 1 s o f f l o a d e d t o s h u t t l e t a n k e r s a p p r o x l m a t e l y
e v e r y f l v e days. Water s e p a r a t e d f r o m t h e e m u l s l o n
1s t r e a t e d t h e n pumped t o Hondo f o r l n j e c t l o n I n t o
The Hondo F i e l d IS l o c a t e d i n t h e Santa dlsposal wells. Sour gas from t h e Hondo P l a t f o r m
Barbara Channel f i v e m i l e s o f f t h e c o a s t o f 1s sweetened from an H S concentration o f appro-
California. The Hondo F i e l d 1 s t h e f i r s t f i e l d x l m a t e l y two and one-ha3f p e r c e n t down t o 35 ppm
t o b e g i n p r o d u c t l o n f r o m t h e S a n t a Ynez U n i t , u s l n g an amme process. The processed gas 1 s used
estimated t o c o n t a i n 300 t o 400 m l l l l o n b a r r e l s o f t o f u e l t w o 1 9 m e g a w a t t (MW) t u r b l n e g e n e r a t o r s
recoverable o i l reserves. Figure 1 i l l u s t r a t e s whlch p r o v l d e power f o r t h e f ~ e l d . A c l d gas from
the l o c a t i o n o f t h e Hondo F i e l d , t h e Santa Ynez t h e 011 and gas s w e e t e n m g o p e r a t l o n s 1s c o n v e r t e d
U n i t , and k e y p r o d u c t i o n s u p p o r t g r o u p s f o r I n t o elemental s u l f u r i n a Claus s u l f u r plant.
Exxon's Santa B a r b a r a Channel o p e r a t i o n s .
The SALM p e r m a n e n t l y moors t h e OS&T 1 - 1 / 2
The Hondo F i e l d i n i t l a l development p l a n i s m i l e s f r o m t h e Hondo P l a t f o r m I n 4 9 0 f e e t o f
shown i n F i g u r e 2. L o c a t e d i n 850 f e e t o f water, water. The SALM has a system o f u n i v e r s a l j o i n t s
the Hondo P l a t f o r m s u p p o r t s d r i l l i n g and p r o d u c t i o n and s w i v e l s w h i c h a l l o w t h e OS&T t o r o l l and p i t c h
activltles for the field. Production a c t i v i t i e s on r e l a t l v e t o a n d w e a t h e r v a n e a b o u t t h e SALM.
the p l a t f o r m i n c l u d e gas-011 s e p a r a t l o n and gas C o n t i n u o u s t r a n s f e r o f e m u l s l o n , gas, and w a t e r
compression, d e h y d r a t i o n , and reinjection. Hondo t h r o u g h t h e SALM w h i l e t h e OS&T w e a t h e r v a n e s i s
c u r r e n t l y produces from 20 w e l l s completed I n two accomplished u s i n g a M u l t i p l e P r o d u c t D i s t r i b u t i o n
d i s t i n c t l y different r e s e r v o u s . The m a j o r i t y o f U n i t (MPDU). E l e c t r i c a l power 1s t r a n s f e r r e d a t 35
crude i s produced f r o m t h e Monterey r e s e r v o i r w h l c h kilovolts (KV) from t h e OS&T t o Hondo t h r o u g h an
y i e l d s a sour l o w g r a v i t y c r u d e t h a t forms a s t a b l e e l e c t r i c a l s l i p r i n g l o c a t e d i n t h e SALM a n d a
e m u l s l o n w i t h w a t e r . P l a t f o r m facilities a r e submerged power c a b l e .
designed t o produce a t o t a l o f 45 thousand b a r r e l s
per day (KB/D) o f c r u d e 011 e m u l s l o n and 26 m l l l i o n Hondo F i e l d O p e r a t i o n - Revlew O f The F i r s t 21 Months
standard c u b i c f e e t p e r day (MSCF/D) o f gas through
two p a r a l l e l p r o d u c t i o n t r a i n s . Produced e m u l s i o n
i s s e p a r a t e d from a s s o c i a t e d gas and pumped v l a an
emulslon p i p e l i n e t o t h e OS&T f o r f u r t h e r p r o c e s - F i g u r e 3 h i g h l i g h t s Hondo F l e l d o i l p r o d u c t l o n
sing. Three MSCF/D o f a s s o c i a t e d gas i s t r a n s - p e r f o r m a n c e s i n c e s t a r t - u p i n A p r l l , 1981. 0 1 1
f e r r e d t o t h e OS&T f o r f u e l usage, two MSCF/D i s p r o d u c t i o n has s t e a d i l y i n c r e a s e d o v e r t h e f i r s t 2 1

References a n d i l l u s t r a t i o n s a t e n d o f oaDer.
I
 2 HONDO FIELD DEVELOPMENT AND PRODUCTION OPERATIONS O T C 4542

months s i n c e s t a r t - u p as a r e s u l t o f the completion Transfer o f crude, gas and water through t h e

o f s e v e n new producing w e l l s and r e d u c t i o n s i n SALM 1s accomplished u s l n g a comblnatlon o f h a r d
f a c i l i t i e s downtime. D u r l n g 1982 o i l p r o d u c t i o n plplng, f l u l d s w l v e l s , hoses, and a m u l t l p l e
averaged almost 37 KB/D and facilities downtlme product d l s t r l b u t l o n u n l t (MPDU). Hard p l p l n g 1s
averaged about t e n percent. r u n e x t e r n a l t o the SALM along t h e r l s e r and lower
p o r t l o n o f the buoy and l n s l d e the upper p o r t l o n o f
Successful operation o f the h i g h l y complex and t h e buoy. Crude and gas l m e s cross the u n l v e r s a l
Interdependent Hondo f a c i l i t i e s r e q u i r e s s i g n l f i - j o l n t s and t r l a x l a l s w l v e l u s l n g two f l u i d s w l v e l s
c a n t f i e l d o p e r a t i o n s and o f f i c e support personnel. f o r each p r o d u c t l l n e a t each location. Another
Hondo's many unique f e a t u r e s p l a c e responsibilities f l u l d s w l v e l 1s used f o r each p r o d u c t l l n e a t the
on the p r o d u c t i o n o p e r a t l o n s personnel t h a t are n o t hlnge j o l n t between the OS&T and yoke. The t r e a t e d
n o r m a l l y encountered i n a t y p i c a l o f f s h o r e f i e l d . water l m e crosses the u n l v e r s a l j o l n t s , t r l a x l a l
F o r i n s t a n c e , the c o n t r o l room operator on the OS&T s w l v e l , and h l n g e j o l n t u s i n g hoses. The MPDU,
must n o t o n l y be experienced I n hydrocarbon process- l o c a t e d I n the upper buoy, a l l o w s t h e continuous
i n g o p e r a t i o n s b u t a l s o w i t h cargo t r a n s f e r and t r a n s f e r o f c r u d e , gas and w a t e r w h l l e t h e OS&T
s h i p b a l l a s t i n g operatlons. F l e l d technicians must weathervanes about the SALM.
be f a m i l i a r w l t h innovative technology such as t h e
SALM's 35 K V s l i p r l n g and MPDU. A t o t a l o f 86 Highlighted i n F i g u r e 6 i s a t y p i c a l SALM
Exxon o p e r a t i o n s p e r s o n n e l s p l i t between two f l u l d swivel. The s w l v e l s two main p a r t s , t h e
crews a r e assigned t o the f l e l d o p e r a t i o n s on a o u t e r body and I n n e r n i p p l e , r o t a t e r e l a t i v e
seven day on and seven day o f f b a s i s . Each crew t o each o t h e r by means o f t a p e r e d r o l l e r b e a r -
c o n s i s t s o f day and n l g h t s h l f t s t o p r o v i d e f o r lngs. Leakage o f t h e s w i v e l s i s p r e v e n t e d b y a
continuous s u r v e i l l a n c e . F i g u r e 4 presents the s e r i e s o f seven s e a l s , i n c l u d i n g f o u r p r o d u c t
Hondo F l e l d p r o d u c t i o n operations organization. s e a l s , between t h e n i p p l e and body. Underwater
Q u a r t e r s a r e available t o board 45 people on Hondo crude o i l s w i v e l s are t l e d i n t o a l e a k d e t e c t i o n
and 30 people on t h e OS&T. system t h a t senses pressure I n the b e a r i n g c a v i t y
between the second and t h i r d p r o d u c t seals. This
Producing from the Hondo F i e l d has r e q u i r e d system i s d e s i g n e d t o p r o v i d e e a r l y w a r n i n g o f
t h e development o f s e v e r a l i n n o v a t i v e deslgn product seal deterloration, allowing appropriate
concepts and o p e r a t i o n a l procedures n o t encountered maintenance t o be performed w e l l i n advance of a
I n t y p i c a l o f f s h o r e f l e l d s . The remainder o f t h i s p r o d u c t s e a l c o n d i t i o n which would r l s k l e a k i n g
paper w i l l dlscuss Exxon's experience w i t h f o u r crude o i l . Each crude and gas s w l v e l above water
aspects o f the p r o d u c t i o n o p e r a t i o n s which d i s t l n - i s equipped w i t h pressure gauges between each o f
g u i s h t h e Hondo F i e l d from o t h e r o f f s h o r e develop- the f o u r p r o d u c t s e a l s t o p e r m i t s u r v e i l l a n c e o f
ments. These i n c l u d e : s e a l performance.

1) Product T r a n s f e r Through The SALM

I The MPDU, a l s o highlighted i n F i g u r e 6, has a
t o t a l o f t h r e e p r o d u c t chambers and s i x hydraulic
2) Power Generation And Distribution
I chambers. Located i n t h e lower s e c t i o n o f t h e MPDU
i n descending o r d e r are t h e gas, water and crude
3) Crude And Gas Processing On An Offshore o i l chambers. The h y d r a u l i c chambers, which p e r m i t
Storage And T r e a t i n g Vessel passage o f h y d r a u l i c f l u i d f o r subsea shutdown
valves, a r e l o c a t e d i n t h e upper s e c t l o n o f the
4) Crude O f f l o a d l n g To S h u t t l e Tankers MPDU. A l l chambers c o n s i s t o f a f i x e d i n n e r
c a v l t y and a r o t a t i n g o u t e r c a v i t y , which i s d r i v e n
Product Transfer Through The SALM

The Hondo SALM's f u n c t i o n a l requirements a r e

I by s t r u c t u r a l arms connected t o the b e a r i n g t a b l e
o f the t r i a x i a l s w i v e l . S e a l i n g between t h e f i x e d
and r o t a t i n g s e c t i o n s o f t h e MPDU 1s accomplished
( 1 ) t o permanently moor the OS&T and ( 2 ) t o p e r m i t w l t h carbon-filled t e f l o n seals. Both sides o f
continuous t r a n s f e r o f t h r e e products and power each h y d r a u l i c and p r o d u c t chamber a r e equipped
between Hondo and the OS&T, w h i l e t h e OS&T i s f r e e w i t h one p r i m a r y and one s e c o n d a r y s e a l . Seal
t o w e a t h e r v a n e a b o u t t h e SALM i n r e s p o n s e t o diameters a r e 22 inches f o r t h e h y d r a u l i c s e a l s and
changing wind and c u r r e n t c o n d i t i o n s . Operatmg i n 50-60 i n c h e s f o r t h e p r o d u c t s e a l s . A pressure
the e n v i r o n m e n t a l l y s e n s i t i v e area o f the Santa gauge i s l o c a t e d between each primary and secondary
Barbara Channel makes i t e s s e n t i a l t h a t no leakage s e a l t o monitor primary s e a l performance.
o c c u r f r o m t h e SALM p r o d u c t t r a n s f e r system.
The SALM product t r a n s f e r system has operated
F i g u r e 5 i l l u s t r a t e s the SALM s t r u c t u r e and s u c c e s s f u l l y over t h e f i r s t 21 months o f p r o d u c t i o n
p r o d u c t t r a n s f e r f e a t u r e s . The SALM c o n s i s t s o f f r o m Hondo, m e e t i n g two i m p o r t a n t p e r f o r m a n c e
t h r e e major components: t h e mooring base, a 248- objectives: ( 1 ) I t has operated w i t h o u t any o i l
f o o t r i s e r , and a 2 1 4 - f o o t buoy. The OS&T i s leakage t o the marine environment and ( 2 ) I t has
connected t o t h e SALM by means o f a 175-foot r i g i d operated c o n t i n u o u s l y , w l t h o u t causlng any produc-
yoke, hinged a t t h e s t e r n o f the OS&T. The yoke t i o n interruptions. A comprehensive s u r v e i l l a n c e
connects t o t h e SALM a t a t r l a x i a l s w i v e l , which i s program i s I n p l a c e t o monitor the performance o f
e s s e n t i a l l y a u n i v e r s a l j o i n t mounted on a bearing t h e MPDU and f l u i d s w i v e l s e a l s . T h i s program
table. The t r i a x i a l s w i v e l p e r m i t s the OS&T t o i n c l u d e s d a l l y o b s e r v a t i o n o f t h e MPDU and a l l
r o l l and p i t c h w i t h r e s p e c t t o t h e SALM w h i l e a l s o above w a t e r s w i v e l s , d a i l y l o g g i n g o f p r e s s u r e
a l l o w i n g the OS&T t o weathervane about t h e SALM. gauge readings on the MPDU, above water s w i v e l s and
U n i v e r s a l j o i n t s connect t h e buoy t o the r i s e r and below water o i l s w i v e l s , and p e r i o d i c underwater
t h e r i s e r t o t h e base, p e r m i t t i n g the s t r u c t u r e t o remote c o n t r o l l e d v e h l c l e surveys o f the underwater
1 f l e x a t these l o c a t i o n s . swivels. Additionally , t o minimize production
 OTC 4542 R.E. OLSON, D.R. OLSEN, J.D. RULLMAN, F.G. VASSER 111 3

downtme associated w l t h a r e p a i r i f i t becomes d l s t r i b u t l o n system have performed w e l l and e x p e r i -

necessary, d e t a l l e d s w l v e l replacement and MPDU ence w i t h t h e s l l p r i n g has been e x c e l l e n t .
overhaul procedures have been developed and a l l P e r l o d i c analyses o f the I n s u l a t i n g 011 f o r d l e l e c -
necessary spare p a r t s and t o o l l n g have been ac- t r l c s t r e n g t h , which i s t h e most d l r e c t method t o
qulred. e v a l u a t e t h e c o n d i t i o n o f the s l i p r i n g assembly,
have shown no appreciable r e d u c t i o n i n insulating
Power Generation And D i s t r l b u t l o n

The deslgn and o p e r a t l o n o f the Hondo F i e l d

I quality. The s u b m a r l n e c a b l e s y s t e m has a l s o
functioned properly without lncldent.
underwater surveys have shown t h a t b o t h the c a b l e
Recent

power g e n e r a t l o n and distribution f a c l l l t l e s and subsurface buoy a r e i n good condition.

presented two major challenges: ( 1 ) To generate
power f o r the e n t i r e f ~ e l don an o f f s h o r e f l o a t l n g Crude And Gas Processing On An Offshore Storage And
vessel and ( 2 ) To t r a n s m l t power t o the p l a t f o r m T r e a t i n g Vessel
w h i l e the OS&T i s weathervanlng about the SALM.
The c o n v e r s i o n o f an o i l t a n k e r i n t o a n
E l e c t r l c a l power f o r t h e f l e l d i s produced by Offshore Storage and T r e a t i n g Vessel, permanently
two 19 MW a i r c r a f t - d e r i v a t i v e t u r b l n e generators. moored t o p r o c e s s c r u d e and gas f r o m a n e a r b y
One hundred percent spare generating c a p a c l t y has p l a t f o r m and s t o r e t r e a t e d crude f o r o f f l o a d i n g t o
been provided, i n t h a t each t u r b i n e generator i s tankers, e s t a b l i s h e d an I n d u s t r y f i r s t . Although
capable o f h a n d l i n g the e n t i r e power demand f o r t h e moored storage vessels are I n o p e r a t l o n throughout
fleld. The t u r b i n e generators are l o c a t e d I n a the world, the OS&T 1s t h e f i r s t f l o a t i n g f a c i l i t y
power p l a n t module i n the s t e r n o f the ship. To t o I n c l u d e b o t h p r o d u c t t r e a t i n g and power genera-
minlmize the impact o f v e s s e l motlon on t h e align- t l o n facilities t o serve an e n t i r e f l e l d .
ment o f the t u r b l n e generator s h a f t s , the base o f
t h e power p l a n t module was c o n s t r u c t e d w l t h r i g l d A process f l o w dlagram f o r t h e OS&T i s shown
supporting beams. I n F i g u r e 8. The sour e m u l s i f i e d crude 011 from
the p l a t f o r m i n i t i a l l y e n t e r s an o i l - w a t e r separa-
The Hondo F l e l d power distribution system i s t l o n system which c o n s i s t s o f a freewater knockout
d e p l c t e d I n F l g u r e 7. One o f the unique aspects o f vessel, heat exchangers, and e l e c t r o s t a t i c t r e a t -
t h e Hondo F i e l d power d l s t r i b u t l o n system i s the ers. Water s e p a r a t e d f r o m t h e e m u l s i o n i s p r o -
power t r a n s m i s s i o n system between t h e OS&T and cessed i n a f l o t a t i o n separator and a filtration
Hondo. This system c o n s l s t s o f an e l e c t r l c s l i p u n l t and t h e n pumped back t o t h e p l a t f o r m f o r
r l n g assembly l o c a t e d I n the SALM which permlts injection. The dehydrated crude o i l e n t e r s s t a b i -
contmuous t r a n s f e r o f electrical power as t h e OS&T l i z e r towers where H S, C O and l i g h t hydrocarbons
weathervanes about the SALM and a 35 K V submarine 2
are removed by h e a t m g and %y adding s t r l p p l n g gas.
power cable. The e l e c t r i c a l s l i p r l n g assembly S t a b i l l z e d crude i s cooled and sent t o cargo s t o r a g e
c o n s l s t s o f r o t a t i n g conductor r l n g s , t o which the tanks. High pressure sour f u e l gas from Hondo and
OS&T f e e d e r c a b l e i s t e r m i n a t e d and s t a t i o n a r y low pressure s t r i p p i n g gas used I n the crude s t a b i -
conducting brushes t o which the submarine cable l l z e r s a r e sweetened I n a p r o p r i e t a r y amine system
from the p l a t f o r m 1s terminated. The s t a t l o n a r y t h a t u t i l l z e s two c o n t a c t o r s and a common regenera-
brushes a r e sprlng-loaded and r i d e on the face o f tor. Acid gas which 1s liberated as a r e s u l t o f t h e
each .conductor r m g . E l e c t r l c a l power 1s t r a n s - amine r e g e n e r a t i o n p r o c e s s i s r o u t e d t o a C l a u s
m l t t e d across t h l s m t e r f a c e . To p r o v i d e e l e c t r l - s u l f u r p l a n t where t h e H S i s c o n v e r t e d t o e l e -
c a l isolation between t h e t h r e e h l g h v o l t a g e 2
mental s u l f u r .
c i r c u i t s , the r o t a t i n g and s t a t l o n a r y components
a r e Immersed i n an i n s u l a t i n g 0 1 1 - f l l l e d chamber. Weather and e n v i r o n m e n t a l c o n s i d e r a t i o n s
The submarlne power cable t r a n s f e r s power from the s l g n i f l c a n t l y i m p a c t e d t h e OS&T p r o c e s s d e s l g n .
s l i p r m g t o the p l a t f o r m approximately 8500 f e e t The facilities were deslgned t o minimize downtame
away. The c a b l e c o n s i s t s o f t h r e e one-half i n c h r e s u l t i n g from OS&T motions, i n c l u d m g r o l l , p i t c h
diameter conductors w i t h armor and j a c k e t construc- and heave, caused by s e v e r e w e a t h e r c o n d i t i o n s .
t l o n t o p r o t e c t a g a i n s t the v a r i o u s environmental S p e c i a l a n t i s u r g e and s h i p motion considerations
I n f l u e n c e s and 'stresses encountered. To mlnlmize were i n c o r p o r a t e d i n t o the facilities: (1) v e r t l -
bending s t r e s s e s associated w i t h SALM f l e x l n g a t c a l pressure vessels were used wherever p o s s i b l e ,
the base and mlddle u n i v e r s a l j o i n t s , the submarine ( 2 ) p r e s s u r e v e s s e l s w h i c h had t o be h o r i z o n t a l
cable i s draped i n a catenary away from the SALM t o because o f processing requirements were equipped
a subsurface buoy, as shown I n F i g u r e 2. w i t h s p e c i a l b a f f l e s and l o c a t e d longitudinally
near the middle o f the s h i p , ( 3 ) packed towers were
Slnce s t a r t - u p t h e Hondo F l e l d power genera- used l n s t e a d o f t r a y e d towers and ( 4 ) d i f f e r e n t i a l
t l o n and d l s t r l b u t l o n f a c l l l t l e s have o p e r a t e d p r e s s u r e sensor r a t h e r than l l q u i d f l o a t l e v e l
s u c c e s s f u l l y , m e e t l n g a l l d e s l g n objectives. m s t r u m e n t s where used. L i g h t w e i g h t and compact
Uptlme f o r t h e f l e l d ' s power generatlon and d l s t r l - equipment, such as t i t a n i u m p l a t e h e a t exchangers,
b u t l o n f a c l l l t l e s has exceeded 99%. The p e r f o r - was used wherever p o s s i b l e t o minimize p l o t space
, mance o f the a l r c r a f t d e r l v a t l v e t u r b l n e s has been requirements and the impact on v e s s e l s t a b i l i t y .
q u i t e good. Boroscope l n s p e c t l o n s have revealed no
appreciable englne d e t e r i o r a t i o n a f t e r approxl- The f a c i l i t i e s on t h e OS&T were d e s i g n e d
m a t e l y 8,000 h o u r s of r u n t l m e on one u n l t and t o minimize a i r and water emissions. The s u l f u r
12,000 h o u r s on t h e o t h e r . A d d i t i o n a l l y , OS&T recovery u n i t , which reduces SO a i r emissions,
motion and f l e x i n g due t o sea conditions has n o t i s the f i r s t o f f s h o r e appllca$ion o f a Claus
had any adverse e f f e c t s on r o t o r alignment. sulfur plant. Gas f l a r i n g i s minimized through the
o p e r a t i o n o f a vapor recovery system. To minimize
1 A l l components o f t h e h i g h v o l t a g e power I water emissions, deck drainage and r a i n water i s
4 HONDO FIELD DEVELOPMENT AND PRODUCTION OPERATIONS OTC 4542

c o l l e c t e d , t r e a t e d and pumped t o Hondo f o r i n j e c - i n g o p e r a t i o n s , a vapor b a l a n c e l i n e system (VBL)

tion. The s h i p b a l l a s t i n g system i s segregated has been employed. As t r e a t e d c r u d e i s pumped
f r o m t h e c r u d e o i l s t o r a g e system t o p r e v e n t o i l t h r o u g h a f l o a t i n g 20-inch c a r g o hose f r o m t h e OS&T
c o n t a m i n a t i o n o f t h e b a l l a s t seawater. t o t h e tanker, displaced cargo tank vapors a r e
c o l l e c t e d on b o a r d t h e t a n k e r , c o m p r e s s e d t o a
D u r i n g t h e f i r s t 2 1 months o f o p e r a t i o n t h e nominal 10 p s l g and r o u t e d back t o t h e OS&T t h r o u g h
OS&T o i l and gas t r e a t i n g systems have performed as a f l o a t i n g e i g h t - l n c h VBL hose. A t t h e OS&T t h e
expected and 1982 u p t i m e f o r t h e OS&T p r o c e s s i n g v a p o r s a r e p u t i n t o t h e c r u d e s t o r a g e t a n k gas
o p e r a t i o n s exceeded 97%. A l l t r e a t e d crude ship- b l a n k e t system. As OS&T crude s t o r a g e t a n k s a r e
ments have satisfied t h e d e s i g n specifications o f subsequently f i l l e d w i t h t r e a t e d crude t h e d l s -
l e s s t h a n t h r e e p e r c e n t w a t e r a n d 1 0 ppm H S. p l a c e d VBL vapors a r e compressed, combined w i t h t h e
The 50 ppm s u l f u r s p e c i f i c a t i o n f o r t h e turb$ne main s o u r f u e l gas stream f r o m t h e p l a t f o r m , and
f u e l gas has been r e l i a b l y achieved. The process- sweetened f o r use as f u e l gas. To a v o i d problems
i n g o p e r a t i o n s have n o t been i n t e r r u p t e d due t o t h a t would be caused by oxygen e n t e r i n g t h e OS&T
v e s s e l motion, w i t h f a c i l i t i e s operating w e l l I n gas system, utilization o f t h e VBL r e q u i r e d t h a t
a l l sea s t a t e s encountered. t a n k e r s o f f l o a d i n g c r u d e f r o m t h e OS&T be equipped
w l t h s p e c i a l i n e r t gas g e n e r a t o r s c a p a b l e o f
M i n i m i z i n g a i r a n d w a t e r e m i s s i o n s 1 s an g e n e r a t i n g t a n k b l a n k e t gas w l t h an oxygen c o n t e n t
important a s p e c t o f t h e OS&T o p e r a t i o n . During o f u n d e r one m o l e p e r c e n t . T y p i c a l cargo tank
1982, t h e C l a u s s u l f u r r e c o v e r y u n i t achieved 92% i n e r t gas b l a n k e t i n g systems, used on t a n k e r s t h a t
u p t i m e and averaged 92% r e c o v e r y v e r s u s a d e s i g n v e n t t h e tank vapors d u r l n q l o a d i n g , produce
r e c o v e r y l e v e l of 93%. No o i l s p i l l a g e from t h e an l n e r t g a s w i t h a c o n s i d e r a b l y h i g h e r o x y g e n
OS&T h a s b e e n e x p e r i e n c e d d u r l n g t h e f l r s t 2 1 content.
months o f o p e r a t i o n .
Because t h e t r e a t e d c r u d e s t o r a g e c a p a c l t y o f
The performance of t h e OS&T p r o c e s s facilities t h e OS&T i s l i m i t e d t o a p p r o x l m a t e l y f i v e days o f
d u r i n g t h e p a s t 21 months, however, has n o t been p r o d u c t i o n , t h e a b i l i t y t o moor t a n k e r s and o f f l o a d
e n t i r e l y trouble free. I n e a r l y 1982, d r i l l l n g mud c r u d e under adverse sea c o n d i t i o n s 1s v e r y Impor-
a c c u m u l a t i o n i n t h e p r o c e s s t r a i n s caused s e v e r e tant. To m i n i m l z e t h e I m p a c t o f a d v e r s e s e a
f o u l l n g o f h e a t exchangers which restricted OS&T c o n d i t i o n s , bow-to-bow m o o r i n g o f t h e OS&T a n d
throughput. The mud h a d e n t e r e d t h e Hondo d r a i n t a n k e r s was s e l e c t e d v e r s u s t h e more c o n v e n t i o n a l
system d u r i n g d r i l l l n g deck washdowns and, by t h e slde-by-side approach. D u r i n g t h e bow-to-bow
n a t u r e o f t h e deck d r a i n system design, was i n t r o - moorlng t h e t a n k e r s a r e connected t o t h e OS&T by a
duced i n t o t h e c r u d e o i l e m u l s i o n f l o w stream and 21-inch circumference hawser r u n n l n g between t h e
t r a n s f e r r e d t o t h e OS&T a l o n g w i t h t h e emulsion. bow o f e a c h v e s s e l . A d d i t i o n a l l y , use o f t h e
T h i s p r o b l e m was s o l v e d a t t h e s o u r c e by I n s t a l l i n g bow-to-bow mooring requires t h a t the tankers
a s e p a r a t e d r a i n system on Hondo i n t h e areas where s e r v i c i n g t h e OS&T be equipped w i t h s p e c i a l e q u i p -
d r l l l i n g mud was b e i n g handled. A l s o I n e a r l y 1982, ment t o h a n d l e t h e h a w s e r , c a r g o h o s e a n d v a p o r
c r a c k i n g was d e t e c t e d i n some o f t h e p l a t e h e a t hose a t t h e bow. Bow-to-bow mooring enables t h e
exchangers. The f a i l u r e mechanism was identified t a n k e r s t o moor and r e m a l n on s t a t l o n i n s l g n i f i -
as s t r e s s c o r r o s i o n c r a c k i n g o f t h e t l t a n i u m p l a t e s c a n t l y g r e a t e r sea s t a t e s t h a n would be p o s s i b l e
caused by hydrogen f l u o r l d e a t t a c k i n a r e a s o f h i g h w i t h t h e more c o n v e n t i o n a l s i d e - b y - s l d e t e c h n i q u e .
r e s i d u a l s t r e s s c r e a t e d by t h e c o l d f o r m l n g p l a t e To f u r t h e r i n c r e a s e t h e a b l l i t y o f t h e t a n k e r s t o
fabrication process. The hydrogen f l u o r i d e was moor under adverse conditions t h e d e d i c a t e d t a n k e r s
b e i n g formed i n a r e a c t l o n between an amine-type used t o o f f l o a d c r u d e f r o m t h e OS&T a r e equipped
c o r r o s i o n inhibitor and t h e f l u o r o c a r b o n g a s k e t w l t h bow t h r u s t e r s . S h o u l d an emergency a r l s e
material. F l u o r o c a r b o n g a s k e t s were o r i g m a l l y durlng the o f f l o a d l n g operation, the tankers are
specified because t h e g a s k e t s would be exposed t o a l s o equlpped w i t h s p e c i a l features t o q u i c k l y
r e l a t i v e l y h i g h t e m p e r a t u r e and H 5. The s o l u - d i s c o n n e c t t h e c a r g o and v a p o r h o s e s a n d t h e
t i o n t o t h i s problem was t o e l l m l n % t e t h e f l u o r o - hawser.
c a r b o n gaskets. N i t r i l e g a s k e t s were substituted
t o a v o i d t h e s t r e s s corrosion c r a c k i n g problem. H o n d o c r u d e l o q l s t l c s a r e influenced b y
Because n l t r i l e i s e x p e c t e d t o degrade over t u n e several factors. F i r s t , utilization o f t h e VBL and
due t o exposure t o H S a t e l e v a t e d temperatures, bow-to-bow mooring r e q u i r e t h a t t a n k e r s o f f l o a d i n g
t h e p l a t e h e a t exchanger 2 manufacturer 1s conducting c r u d e f r o m t h e OS&T h a v e s p e c l a l e q u i p m e n t n o t
r e s e a r c h t o i d e n t i f y a more s u i t a b l e gasket m a t e r i a l f o u n d on t y p l c a l t a n k e r s . Second, m o s t o f t h e
Hondo c r u d e i s r e f l n e d a t E x x o n ' s Baytown, Texas
Crude O f f l o a d i n g To S h u t t l e Tankers r e f l n e r y thus r e q u i r i n g the tankers t o t r a n s l t the
Panama Canal. T h i r d , t h e OS&T s t o r a g e c a p a c l t y 1s
C r u d e o f f l o a d i n g f r o m t h e OS&T h a s b e e n l l m i t e d t o 210k b a r r e l s o r a p p r o x l m a t e l y f l v e days
influenced by three s i g n i f i c a n t factors: (1) a i r production. To accommodate these f a c t o r s a f l e e t
e m i s s i o n s , ( 2 ) t a n k e r m o o r i n g c a p a b i l i t i e s and ( 3 ) o f f l v e d e d i c a t e d s h u t t l e t a n k e r s has been assem-
logistics. These t h r e e f a c t o r s have r e s u l t e d I n b l e d a n d specially e q u l p p e d t o t r a n s p o r t Hondo
t h e d e v e l o p m e n t o f some i n n o v a t i v e s y s t e m s a n d c r u d e f r o m t h e Santa B a r b a r a Channel t o Baytown.
unlque operating p r a c t i c e s . The t a n k e r s v a r y i n c a p a c l t y f r o m 235k t o 300k
barrels. To p r o v i d e a d d l t l o n a l flexibility a n d
Typical tanker loadlng operations r e s u l t i n back-up coverage f o r p e r i o d s o f t i m e when one o f
a t m o s p h e r i c v e n t i n g o f l n e r t gas and hydrocarbon t h e f ~ v et a n k e r s may b e o u t o f s e r v i c e , a s i x t h
v a p o r s f r o m t h e c a r g o t a n k s as t h e t a n k e r s a r e t a n k e r equipped w i t h VBL equipment and bow-to-bow
f i l l e d w i t h crude. I n an e f f o r t t o e l l m l n a t e m o o r i n g capability 1 s a v a i l a b l e t o make c r u d e
h y d r o c a r b o n a i r e m i s s i o n s d u r i n g OS&T o f f l o a d - shipments t o West Coast d e s t i n a t i o n s .
O T C 4542 R.E. OLSON, D.R. OLSEN, J.D. RULLMAN, F.G. VASSER I11 5

To date crude o f f l o a d l n g o p e r a t l o n s have been performance o f the many unique f e a t u r e s a s s o c i a t e d

successful. The v a p o r b a l a n c e l i n e system has w i t h the Hondo development. Through t h e s u c c e s s f u l
been used t o e s s e n t i a l l y eliminate h y d r o c a r b o n o p e r a t l o n s o f the many interdependent systems on t h e
emissions. Mooring o p e r a t i o n s have been delayed by Hondo P l a t f o r m , the Offshore Storage and T r e a t i n g
weather c o n d i t i o n s once, w i t h a t o t a l impact on Vessel and the S i n g l e Anchor Leg Mooring, Exxon has
p r o d u c t i o n o f l e s s than one day. Tanker l o g i s t i c a l extended the deepwater p r o d u c t i o n and processing
o p e r a t i o n s have been a c c o m p l i s h e d w i t h o u t one c a p a b i l i t i e s o f the i n d u s t r y and 1s g a i n i n g o p e r a t -
I n c i d e n t o f production c u t b a c k because o f OS&T i n g experience t h a t w l l l be b e n e f i c i a l as e f f o r t s
storage c a p a c i t y l i m i t s . proceed t o develop the remaining reserves i n the
Santa Ynez U n i t .
Through actual operating e x p e r i e n c e some
evolution o f crude o f f l o a d i n g equipment and proce- References
d u r e s has o c c u r r e d . The o r i g l n a l l i g h t w e i g h t
vapor balance hose had a tendency t o k i n k and i t G o d f r e y , J.W., B a r a k l s , S.E., D e v i n e , W.B. and
has been replaced by a more rugged hose. I t was Fedak, M.E. " O f f s h o r e S t o r a g e and T r e a t i n g o f
expected t h a t the hawser and hoses, which a r e l e f t Crude O i l Aboard a M o d i f i e d O i l Tanker." O T C
i n the water when n o t i n use, would stream away Paper 4271 presented a t the 1982 Offshore Tech-
from the OS&T thus e n a b l i n g the tankers t o r e t r l e v e nology Conference, Houston, May 3-6.
them w i t h o u t t h e a s s i s t a n c e o f a work b o a t .
Immediately a f t e r s t a r t - u p severe t a n g l i n g o f the B u t l e r , Jr., A.Y., Reed, D.C. and Vasser, 111, F.G.
hawser and hoses was experienced unless they were " E l e c t r i c Power S l l p R i n g Assembly f o r M a r l n e
individually t i e d o f f t o t h e OS&l a f t e r each R l s e r Systems." OTC Paper 4356 presented a t the
loadlng. Thls has r e q u i r e d t h a t a work boat a s s i s t 1982 Offshore Technology Conference, Houston, May
w l t h each crude t r a n s f e r operation. 3-6.

Conclusions H o f f e r b e r , J.E., Masnada, D.A. and Deacon, N.A.

"SALM I n s t a l l a t i o n i n Santa Barbara Channel." SPE
Through t h e f i r s t 21 months Hondo F l e l d Paper 10212 p r e s e n t e d a t t h e 5 6 t h A n n u a l F a l l
o p e r a t i o n s have produced, t r e a t e d and o f f l o a d e d 21 Technical C o n f e r e n c e and Exhibition o f t h e
m i l l i o n b a r r e l s o f 011. The success o f the Hondo S o c i e t y o f P e t r o l e u m E n g i n e e r s o f AIME, San
o p e r a t l o n s can be l a r g e l y a t t r i b u t e d t o the good Antonio, October 5-7, 1981.

CALIFORNIA DRILLING OFFICE

SANTA INEZ UNIT HONDO SPARE

PARTS WAREHOUSE

-
0 10
Scale
20mi.

Fig. I-Exxon's Santa Barbara Channel operations.

 TANKER

Fig. 2-ln~ttal Hondo fleld development

OIL PRODUCTION

z 20
1
0

A M J J A S O N D J F M A M J J A S O N
198 1 1982

Fig. 3-Hondo fleid oll production-the flrst 21 months

 Instrumentation SUPERINTENOENT Superintendent
i- - - -4
, , 7
Construction

,PLATFORM !
I

Field Foreman
,FIELD
Technical Foreman
! Foreman
I

Shift Foreman

Lease Operator Special 8

Senior Technician
Maintenance Specialist 16 Product Analyst

I Total: 43 oer Craw 1

Fig. 4-Hondo field product~onorgantzation.

------------0 NWIWWNWWWrrCI

6", 8" & 12" CARCO LINES

Fig. 5-SALM elevation vtew

 TYPICAL FLUID SWIVEL MULTIPLE PRODUCT OlSTRlBUTlOW U l l l
IMPDUI
PRESSURE OBSERVATION POINTS

BODY-

NIPPLE -

LUBRICANT
IWJEGTlON POINT

Fig. 6-SALM
- FLUID FLOW

product transfer system highlights

-
SALM SLIP RING

I 2
0 1 8 1 VESSEL SLCywO S U B ~ E ~

Ftg. 7-Hondo heid power d!str~but~on

sysiem

OIL/WATER
FROM EMULSION OIL/WATER OIL OIL OIL OIL STORAGE OIL TO
PLATFORM r61(8PO- SEPARATION 40KBPD HOOPPM y ) STABILIZATION 40KBPO IIOPPM H2Sl+ l210KBBLSl 'TANKERS

1 I

, po5, 5
WATER
5KBWPD

SWEET AMINE

FOR TREATING SWEETENING

FROM PLATFORM
SOUR FUEL GAS
-2.1phy J A
m
B
;E
lR
EXHUT TU WASTE
HEAT REWVERY

TO ELECTRIC POWER SULFUR GAS

GENERATION RECOVERY INCINEPAlOR

SULFUR 193%)
TANKS

Fig. 8-OS8T process flow schernatlc