SPE LONDON MEETINGS 2013 SUBSEA PRODUCTION AND FLOW ASSURANCE BY; - - PowerPoint PPT Presentation
SPE LONDON MEETINGS 2013 SUBSEA PRODUCTION AND FLOW ASSURANCE BY; - - PowerPoint PPT Presentation
SPE LONDON MEETINGS 2013 SUBSEA PRODUCTION AND FLOW ASSURANCE BY; SACHA SARSHAR,CALTEC www.caltec.com SUBSEA PRODUCTION &FLOW ASSURANCE WHY SUBSEA PRODUCTION ? KEY PARAMETERS SUBSEA PROCESSING OPTIONS FLOW ASSURANCE IN WELLS
SUBSEA PRODUCTION &FLOW ASSURANCE
- WHY SUBSEA PRODUCTION ?
- KEY PARAMETERS
- SUBSEA PROCESSING OPTIONS
- FLOW ASSURANCE IN WELLS
- FLOW ASSURANCE IN SUBSEA PIPELINES/RISERS
- HISTORY OF SS SEPARATION & BOOSTING SYSTEMS
- FIELD EXAMPLES
- THE FUTURE NEEDS AND ASPIRATIONS
- TECHNOLOGY GAPS/CONCLUSIONS
22 February, 2013 Presentation title 3
A TYPICAL SUBSEA PRODUCTION SYSTEM DEEP WATER APPLICATION Production, manifolding, gas lift, water injection, ,separation, pumping, compression
22 February, 2013 Presentation title 4
A TYPICAL SUBSEA PRODUCTION SYSTEM
WHY SUBSEA PRODUCTION?,KEY PARAMETERS
- DEEP/DEEPER WATER FIELDS,HIGH COST OF MORE
THAN ONE DEDICATED PRODUCTION PLATFORMS
- SHALLOW TO MEDIUM WATER DEPTH; TRANSPORT
OF FLUIDS FROM SATELLITES OR NEW FIELDS TO A HOST PLATFORM
- HOSTILE ENVIRONMENTS, LONG DISTANCE
TRANSPORT TO A MORE BENIGN ENVIRONMENT
- DEEP WATER/LONG DISTANCE PIPELINES, PRESSURE
LOSS RESTRICTING PRODUCTION &RECOVERY+OTHER FLOW ASSURANCE PROBLEMS
- RISER GENERATED PROBLEMS
SUBSEA PRODUCTION,MAIN BENEFITS
- INCREASED TOTAL RECOVERY
- ENABLING PRODUCTION FROM DEEP
WATERS AND HOSTILE ENVIRONMENTS
- LOWER CAPEX/OPEX-CONVENTIONAL
PRODUCTION PLATFORMS IN DEEP WATERS HAVE MUCH HIGHER CAPEX &OPEX
- ENABLES LONG DISTANCE TRANSPORT OF
FLUIDS TO EXISTING HOST PLATFORMS
- HSE BENEFITS
22 February, 2013 Presentation title 6
MAIN CAUSES OF RESTRICTIONS TO PRODUCTION & TOTAL RECOVERY
- Low reservoir pressure/aging field
- Tight, fragmented resevoirs,poor Permeability /PI
- Deep reservoirs/deep wells-long flow path
- Low GOR /liquid loading
- Rising water cut
- Long distance transport (Satellites)
- High density and viscosity oil
- Poor well inflow characteristics
- Topside Process system pressure requirements
- Hostile environments ,e.g. Arctic
A boosting system is therefore needed to maintain
- r increase production and total recovery
HOW TO MAINTAIN PRODUCTION AND IMPROVE RECOVERY
Primary recovery
Natural flow
Artificial lift
Others
RR 50% to 80% Steam, Hot water, combustion
Microbial, Acoustic, Electromagnetic
IOR EOR
Pressure Maintenance SS Production/boosting Secondary recovery Chemical
Thermal Gas injection
Rate of Recovery (RR) Less than 35% RR 30%-50% CO2,N2,etc. Alkali,Surfactant, Polymer
Surface boosting
systems
Tertiary recovery
WATER FLOODING
SOLUTIONS TO MAINTAIN OR BOOST PRODUCTION AND TOTAL RECOVERY
- MAINTAIN RESERVOIR PRESSURE. E.G. WATER INJECTION
- IOR and EOR TECHNIQUES
- ENHANCE INFLOW CONDITIONS E.G. ACIDIZE/FRACKING.
- DOWNHOLE ARTIFICIAL LIFT;GAS LIFT,ESPS, FOAM INJECTION
- ETC. PROBLEMS OF HORIZONTAL WELLS
- SUBSEA PRODUCTION &BOOSTING-DEEP OR HOSTILE WATERS
- EXTENDED REACH HORIZONTAL WELLS
- LOWER FLOWING WELLHEAD PRESSURE (FWHP)-VARIOUS
METHODS ,INCLUDING SURFACE JET PUMP (SJP)SYSTEMS
SOLUTIONS DICTATED BY ECONOMICS ,RISKS AND FIELD/PLATFORM CONSTRAINTS.
Combined solutions are often needed
22 February, 2013 Presentation title 9
PRODUCTION FLOW PATH
22 February, 2013 Presentation title 10
RESERVOIR WELLHEAD PIPELINE MANIFOLD PIPELINE SLUG CATCHER RISER TOPSIDE PROCESS EXPORT WELL BORE SS BOOSTING
IOR/EOR 4D- SESMICS
- ARTIFICIAL
LIFT
- EXTENDED
REACH
- FLOW
ENHANCING SOLUTIONS
- XMAS TREE
- INJECTION
SYSTEM
- PRESSURE LOSS
- FLOW REGIME/SLUGS
- TEMPERATURE
- CORROSION
- EROSION
- NASTIES;WAX,SCALE..
,ETC
- PIPELINE INTEGRITY
- CONNECTORS
- VALVES
- INSTRUMENTS
- METERING
- FRAME
- MPH PUMPS
- SS SEP`N+
PUMP.
- GAS
COMPRESSION AS ABOVE
- SLUG CATCHER
- L.PUMPING
- SLUGGING
- DP
- INTEGRITY
- PROCESS
- BOOSTING
SYSTEMS
- PUMPING
COMP`N
COMMON SS COMPONENTS/ISSUES
- MODULARISATION
- CONNECTORS
- INSTRUMENTS
- POWER SUPPLY (ELECTRIC,EH,HYDRAULIC)
- DATA TRANSMISSION
- ACCESS
- IMR/SERVICE VESSEL REQUIREMENTS
22 February, 2013 Presentation title 11
MODULARISATION
February 13 Presentation title
SUBSEA TEMPLATE AND MODULES INSTALLATION AND RETRIEVAL
22 February, 2013 Presentation title 13
MOON POOL
22 February, 2013 Presentation title 14
MULTI-BORE SS CONNECTOR KEY FEATURES;
- MULTIBORE
- SEALS
- ACTUATORS
- ELECTRIC/HYDRAULIC
POWER
- SHOULD BE RETRIEVABLE
- SEALS IN RETRIEVABLE
PART
- PURGING FEATURE
- HORIZONTAL OR VERTICAL
SS MULTIBORE CONNECTOR
22 February, 2013 Presentation title 15
EOR OPTIONS TO ENHANCE RECOVERY STATE OF ART
WELL BORE FLOW ASSURANCE
- MINIMISE PRESSURE LOSS
- FLOW REGIME /PREVENT LIQUID LOADING
- PROBLEM OF HORIZONTAL WELLS
- ARTIFICIAL LIFT SOLUTIONS ( ESP,JET PUMP,GAS
LIFT,FOAM, ETC.)
- VELOCITY STRING (GAS APPLICATION)
- CHEMICALS-SALINITY REDUCING,VISCOSITY
REDUCING ETC.
- REDUCE WELLHEAD PRESSURE
22 February, 2013 Presentation title 16
WELLBORE, FLOW REGIME MAP
- ARTIFICIAL LIFT METHODS
- GAS LIFT
- ESPs
- CHEMICAL
INJECTION(FOAM)
- VELOCITY
STRING (GAS)
- JET PUMPS
22 February, 2013 Presentation title 17
Slug Annular Mist Froth Bubble
Superficial Liquid Velocity (m/s)
SUPERFICIAL GAS VELOCITY (m/s)
22 February, 2013 Presentation title 18
SUBSEA LIUHUA FIELD ,S-CHINA SEA
22 February, 2013 Presentation title 19
25 SS ESPs IN OPERATION FOR NINE YEARS
FLOW THROUGH SS PIPELINES
- PRESSURE LOSS (H.HEAD+FRICTION)
- FLOW REGIME,SLUGGING,LIQUID BUILD-UP
- TEMPERATURE/HYDRATES
- NASTIES; SAND,SCALE,WAX,ASPHALTENE ETC
- CHEMICALS,INHIBITORS,DRA, ETC.
- PIGGING REQUIREMENTS
- CORROSION/EROSION
- PIPELINE INTEGRITY
- METERING
22 February, 2013 Presentation title 20
PRESSURE&TEMPERATURE PROFILE FOR GAS LINE
22 February, 2013 Presentation title 21
EFFECT OF TURN DOWN IN GAS RATE
22 February, 2013 Presentation title 22
Chevron, USA (GOM)
Solution ; HP gas from the existing compressor
- n recycle used to power the jet pump
(Php/Plp=4.9.Qhp/Qlp= 2.11,Pd/Plp=2 ) Benefits Lowered arrival pressure at the platform by 200 psi enabling loaded wells to produce consistently
- Higher gas velocities, lowered liquids
accumulated in the pipeline, causing a further 140psi drop at the wellhead
- Production increased by 24% due to wellhead
pressure reduction and lower pipeline loss.
- 2.5 Bscf of otherwise lost reserves recovered.
Export 40MMSCFD 7.4 MMSCFD 850 psig 400 psig 200 psig Ejector 1250 psig Sales Sub sea manifold Recycle gas
GEMINI
process 22 February, 2013 Presentation title 23
22 February, 2013 Presentation title 24 10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 % OF TOTAL PRESSURE DROP GAS FLOWRATE (MMSCFD)
ELEVATION FRICTION
PRESSURE LOSS DISTRIBUTION-SS GAS PRODUCTION
WATER DEPTH 2,000m
22 February, 2013 Presentation title 25
22 February, 2013 Presentation title 26
TYPICAL PRESSURE LOSS ALONG PIPELINES
22 February, 2013 Presentation title 27
HIGH PRESSURE DROP DEMANDS SS BOOSTING SYSTEMS TO IMPROVE PRODUCTION &RECOVERY
50 100 150 200 250 5 10 15 20 25
PRSSURE (BAR) TEMPERATURE (⁰C) HYDRATE FORMING REGION STABLE NON FORMING REGION
TYPICAL HYDRATE FORMATION CURVE
IF YOU CANT MEASURE, YOU CANT CURE OR IMPROVE
- THE NEED FOR DATA COLLECTION,
DOWNHOLE,INDIVIDUAL WELLS, SUBSEA LINE AND SUBSEA EQUIPMENT
- RELIABLE INSTRUMENTS ARE NEEDED
- RELIABLE DATA TRANSMISSION IS NEEDED
- RELIABLE AND EFFICIENT DATA MANAGEMENT
SYSTEM IS NEEDED
22 February, 2013 Presentation title 29
SUBSEA METERING/WELL TESTING
- KNOWLEDGE OF PRODUCTION RATE OF
G/W/OIL IS IMPORTANT FOR MANAGEMENT OF PRODUCTION
- METERING PRODUCTION FROM SATELLITE
WELLS IS ALSO NEEDED
- NO RELIABLE SS MULTIPHASE METERING
SYSTEM EXISTS, BUT SOME HAVE BEEN USED
- FOR TESTING SS WELLS A TEST MANIFOLD +
METRING SYSTEM IS NEEDED
- ACCURACY OF METRING MAY HAVE TO BE
COMPROMISED FOR THE TIME BEING
22 February, 2013 Presentation title 30
CHEMICAL INJECTION
A variety of chemicals are introduced at wellhead to achieve flow assurance, including;
- HYDRATE INHIBITOR
- CORROSION INHIBITOR
- DRAG REDUCING AGENT
There are also chemicals injected downhole;
- CORROSION INHIBITOR/SCALE INHIBITOR
- WATER TO REDUCE SALINTY OF PRODUCED WATER
- FOAMING AGENT/OTHER COCKTAILS&SOLVENTS
22 February, 2013 Presentation title 31
PIGGING REQUIREMENTS
- MOST PIPELINES REQUIRE PIGGING TO CLEAN
THE LINE OR TO INSPECT THE LINE INTERNALLY
- SS PIG LAUNCHER AND RECEIVER ARE NEEDED
- THERE IS A REASONABLE TRACK RECORD
- INCREASE IN OPEX & CAPEX IF ALL PIGGING
SYSTEM IS SUBSEA ;
- THERE IS EXPERIENCE IN SS PIGGING
22 February, 2013 Presentation title 32
RISER GENERATED PROBLEMS
- SLUG GENERATION –EFFECT OF RISER PROFILE
- PRESSURE LOSS/ FLOW SURGE/SLUGGING
- GAS LIFTING AT BASE OF RISER
- SLUG CATCHER AT THE BASE OF RISER
- RISER STRUCTURAL INTEGRITY-SLUG EFFECT
- NEW TECHNIQUE TO MINIMISE RISER
GENERATED SLUGGING
22 February, 2013 Presentation title 33
22 February, 2013 Presentation title 34
1984
General Slug Control Structure Cranfield university
- Measurement candidates:
– Different pressures – Different flow rates – Density – Levels
- Alternative actuators
– Riser outlet choke – Gas outlet choke – Gas injection
PT FT PT PT LT PC LC DT FT FT Measurement Selection Actuator Selection
Inferential Slug Control (ISC) on Cranfield Facility
VR
Ethernet
Neftemer DeltaV Three-phase Facility Inferential Slug Controller RS232 OPC Link Coriolis
ISC Experimental Results
- Qa=20 Sm3/r, Qw=2kg/s;
Top Valve stabilized around 26% of opening
PCA 3 6 200 400 600 800 1000 1200 1400 1600 1800 Riser Top Valve 20 35 50
200 400 600 800 1000 1200 1400 1600 1800
%
Riser DP 0.5 1 1.5
200 400 600 800 1000 1200 1400 1600 1800
Barg
Riser Top Density
500 1000 200 400 600 800 1000 1200 1400 1600 1800
Time [s] kg/m3
Control Starting Point
JET PUMP TECHNOLOGY
- JET PUMPS HAVE POTENTIAL APPLICATIONS FOR SUBSEA
- BEING A PASSIVE DEVICE WITH NO MOVING PARTS ,ARE IDEAL FOR SS
- TO COPE WITH CHANGING FIELD CONDITIONS ,TWO OR THREE UNITS
CAN BE INSTALLED
- THEY CAN ALSO BE EASILY RETRIEVED AS A MODULE
- THEIR MAIN USE SO FAR HAS BEEN DOWNHOLE
Removabl e Nozzle Removable Mixing tube / Diffuser
Patented Universal Design Jet Pump
SS MULTIPHASE PUMPS
- BASICALLY TWO TYPES;HELICO AXIAL,TWIN
SCREW- MAINLY TWO PLAYERS
- HIGH POWER CONSUMPTION- 1 TO 3.5 MW
- CAN TOLERATE UP TO 100% GAS FOR A SHORT
PERIOD
- VARIABLE SPEED DRIVE IS NEEDED
- CLAIM MTBF OF 4 TO 8 YEARS!
- TRACK RECORD; 5-10 YEARS,BUT ONLY A FEW
UNITS HAVE BEEN INSTALLED
22 February, 2013 Presentation title 39
COMPARISON OF POWER REQUIREMENTS FOR MPP VS SPP
22 February, 2013 Presentation title 40
PROS AND CONS OF SS MULTIPHASE PUMPING PROS;
- No separation of gas/liquids is needed
DISADVANTAGES;
- Complexity of the system
- High power requirement (200 KW to 3MW)
- Complexities of high power supply
- Challenges of variable speed drive
- Heavy weight (100 to 200 tonnes)
- Limited track record/MTBF?
22 February, 2013 Presentation title 41
BORNEMANN SS MPHP
22 February, 2013 Presentation title 42
SUBSEA MULTIPHASE PUMPING MODULE
22 February, 2013 Presentation title 43
OPERATORS SUBSEA TRACK RECORD
STATOIL
- SS PROCESSSING STARTED 1997,LUFENG FIELD
- 500 SUBSEA WELLS
- TARGET FOR STANDARD SS FACTORY BY 2020
PETROBRAS
- FIRST SS SYSTEM 1979
- 800 SS WELLS
- 16 SS ESPS
- FULL SS SEPARATION+ SS WATER INJECTION
22 February, 2013 Presentation title 44
22 February, 2013 Presentation title 45
22 February, 2013 Presentation title 46
22 February, 2013 Presentation title 47
TOTAL-PAZFLOR WEST AFRICA SS SEPARATION AND BOOSTING
22 February, 2013 Presentation title 48
3 IDENTICAL SS SEPARATORS EACH 800 TONNES G-L SEPARATION+ BOOSTER PUMP
PETROBRAS TRACK RECORD
- FIRST SS TREE 1979
- 800 SS WELLS
- 16 DOWNHOLE SS ESPS
- 16 MUDLINE ESPS
- 1 HELICOAXIAL MPP
- 3 SS RAW WATER INJECTION
- 1 SS SEPARATOR
- 1 SS OIL-WATER SEP
CHALLENGES;
- ASSETS DONT FUND DEVELOPMENT WORK
- INTERFACES ARE TOO COMPLEX
- TOO MUCH TOPSIDE EQUIPMENT NEEDED
- TOO COSTLY SYSTEMS
22 February, 2013 Presentation title 49
MARLIM SUBSEA SYSTEM ,Brazil-OIL-WATER SEP,SS OIL PUMP,SS WATER INJECTION PUMP,SS CYCLONIC WATER TREATER- 100 PPM OIW
22 February, 2013 Presentation title 50
SUBSEA SEPARATION
- G-L SEPARATION- GAS TRANSPORTED
UNAIDED,LIQUIDS BOOSTER FOR LIQUIDS
- OIL-WATER SEPARATION-INJECT WATER TO
RESERVOIR
- G-L SEPARATION- SS COMPRESSION + SS
LIQUIDS PUMPING
22 February, 2013 Presentation title 51
FIRST SS SEPARATOR TRIALS ZAKUM FIELD-BP-1969-72
22 February, 2013 Presentation title 52
WATER DEPTH 20M !
February 13 Presentation title
GASPS/GLASS
GA SUBSEA PRODUCTION SYSTEM
1990
22 February, 2013 Presentation title 54
VASP SEPARATOR
ESP
TORDIS SS SEPARATION SYSTEM
22 February, 2013 Presentation title 55
170 TONNES 9,000 sm3 /d oil 24,000 sm3 water Op.pressure;25- 40bar
22 February, 2013 Presentation title 56
22 February, 2013 Presentation title 57
I-SEP HI-SEP I-SEP I-SEP
HI-SEP
22 February, 2013 Presentation title 58
59 22/02/2013
Caltec inline Oil/Water separator (WX), Debottlenecking three phase separators
Caltec Oil-Water Separator (3750 bpd) Samples obtained: 1) Fluid from Final Polishing Unit 2) Caltec clean water outlet 3) Caltec oil outlet sample
2 1 3
February 13 Presentation title
KAVERNER BOOSTER STATION PROTOTYPE G-L SEPARATOR COMPRESSOR DP;45 BAR QL;10,000 B/D QG;6-7 MMSCFD
22 February, 2013 Presentation title 61
SUBSEA COMPRESSION FOR ORMAN LANGE
12.5MW PILOT SS GAS COMPRESSION SYSTEM-
- 860 m water depth, dp 60 bar
22 February, 2013 Presentation title 62
SUBSEA COMPRESSOR
CHALLENGES FOR SUBSEA EQUIPMENT
- RELIABILITY/MTBF- 5 to 8 years or longer
- RETRIEVABILITY/ surface vessel needed
- IMR REQUIREMENTS
- AVAILABILITY (REDUNDANCY)
- ENVIRONMENTAL ISSUES (LEAKS,RUPTURE..)
- TRACK RECORD
- IMPACT IF IT DOES NOT WORK
- COST
- ACCEPTANCE CRITERIA-APPROVALS
22 February, 2013 Presentation title 63
KEY ISSUES AFFECTING RELIABILITY
- RELIABILITY OF INDIVIDUAL COMPONENTS
- SYSTEM COMPLEXITY; NUMBER OF COMPONENTS
AND THEIR FUNCTION/TYPE; MECHANICAL,ELECTRICAL,HYDRAULIC,SIGNAL,ETC
- TOTAL SYSTEM RELIABILITY
- REDUNDANCY
- RETRIEVABILITY/ACCESS
- COST OF RETRIEVAL/IMR (SERVICE VESSEL
REQUIREMENTS)
22 February, 2013 Presentation title 64
HOW TO IMPROVE RELIABILITY AND MTBF
- IMPROVE INDIVIDUAL COMPONENTS
- ADD REDUNDANCY FOR SOME KEY COMPONENTS
- SHARE EXPERIENCE TO CORRECT OR UPGRADE
WHAT HAS GONE WRONG BEFORE
- HAVE SUFFICIENT PROTOTYPE FULL SCAE TRIALS
- ASSESS FULL SYSTEM OPERATION &INTEGRITY, AS
WELL AS KEY COMPONENTS
- SUPPORT DEVELOPMENT WORK TO IMPROVE
COMPONENTS
- STANDARDISE KEY INTERFACE COMPONENTS
22 February, 2013 Presentation title 65
22 February, 2013 Presentation title 66
CLOSING REMARKS
- SUBSEA PRODUCTION HAS PROGRESSED SLOWLY IN
STEPS SINCE 1970s. IT IS NEEDED TO ACHIEVE HIGH RATE OF TOTAL RECOVERY FOR MANY FIELDS
- SS WELLS , MANIFOLDING AND MODULARISATION
HAVE REACHED MATURITY, ROOM FOR IMPROVEMENT FOR COMPONENTS IN ALL AREAS
- SS SEPARATION HAS NOT PROGRESSED BEACAUSE OF
LACK OF FULL SUPPORT-ROOM FOR IMPROVEMENT!
- MPHPs HAVE PROGRESSED, BUT NEED IMROVED
MTBF,SS COMPRESSION IS IN ITS INFANCY
Presentation title 67
CLOSING REMARKS... CONTINUED
- HIGH INVESTMENT IS NEEDED TO DEVELOP &
IMPROVE SS EQUIPMENT/SYSTEMS- WHO PAYS FOR IT?- OPERATOR,EQUIPMENT SUPPLIER?
- GLOBAL SS MARKET HAS RISEN FROM $18 BILLION IN
2003 TO $45 BILLION IN 2012
- EXTENSIVE FAT AND FULL SCALE SYSTEM TRIALS ARE
NEEDED FOR THE SS SYSTEM
- COLLABORATION BETWEEN OPERATORS AND
SUPPLIERS OF SS EQUIPMENT/SYSTEM IS NEEDED TO SHARE COSTS/RISKS/REWARDS
- STANDARDISATION/STANDARDS ARE NEEDED TO
IMPROVE RELIABILITY/HSE AND SIMPLIFY QUALIFICATION/APPROVALS
22 February, 2013 Presentation title 68
22 February, 2013 Presentation title 69