Flow Assurance Technology Options & Pipe Sizing for Deep-Water & Long Distance Oil & Gas

Transport.

Agenda
Introduction Flow Assurance Challenges. Flow Assurance Solution Options. Technologies- GTLA. Design Process Through an Integrated System Approach. Multiphase Pipe sizing Charts Summary

Flow Assurance
The ability to produce fluids economically from the reservoir to a production facility, over the life of field in any environment Deepstar.
The term Garantia de Fluxo Coined by Petrobras in the early 1990s, and translates literally as Guarantee the Flow.

Flow Assurance ?
To produce and transport fluids from the pore throat of reservoir to the host facility Throughout life cycle of field Under all operating conditions In a cost-effective way A structural engineering analysis process that utilizes the in-depth knowledge of fluid properties and thermal hydraulic analysis of the system to develop strategies for control of solids such as hydrates, waxes, asphaltenes and scale OTC #13123

Forget flow assurance Industry needs performance assurance

Keep the flow path open! Goals: Reduce risk of lost or reduced production Enhance production rate FA strategies must be integrated into overall systems design and field operations SL-Shell

Costly and conservative FA Engineers Trouble makers Typical Subsea Engineer

The broadest link throughout the production system Cross-Functional, Cross-Team Discipline From Project Conception to Operations

Flow Assurance Challenges

Paraffin / Ashphaltenes

Gas Hydrates

Emulsion / Foam

Scales

Flow Assurance

Corrosion

Liquid Slugging Low Temperatures

Sand / Erosion

Gas Hydrates: Formation & Structure

Solid Ice-like crystal Hydrocarbon molecules trapped inside water cages Hydrate Formation occurs when Water + light HC Formation temperature (higher than freezing) depends on pressure, can form > 15 C Approximately 85% water, 15% HC Gas volume 150-200 scf/ft3 hydrates

What Problems Can Hydrates Cause?

Blockage of pipeline and flowline Block line completely Plugs up to 6 miles Plugs in up to 40 pipe Production downtime Time and cost of remediation Serious safety issues During drilling or completion Plug blow out preventers Collapse tubing and casing Worsens as water depth increases Spans life cycle of field

Courtesy of Petrobras

Compositional Tracking

Normally Based on Hydrate Dissociation Curve

Reservoir Composition is usually used.

However the composition varies with Shut Down Compositional Tracking of Benefit Increased cool down time Reduced Insulation Requirements Precious additional time prior to hydrates

Pipeline / Riser System during Shut Down

Gas

Oil/Wat

Case Example
Hydrate Curves for Pipeline Shut Down (GOR=3000scf/stb)
180

160

140

120 Pressure (Bara)

100

29 Barg Shutdown 95 Barg Shutdown 95 Barg Flowing

80

60

40

20

0 0 5 10 15 20 25 30

Temp.(C)

Cool Down at Riser Mid Point

Cool down at Riser Mid Point
60 (bopd) 24788 30709 50 36491 42131 47632 52991 58210 Temp.(C) 63289

40

Reservoir Composition
30

Shut in Composition
20

10

Time (Hrs)

Cool Down at Pipeline Inlet

Cooldow n at Pipe Inlet

60

50

(bopd) 24788 30709 36491 42131 47632 52991 58210 63289 Hydrate Tem p
32.5 35.8 38.1 40.3 33.6 34.7 39.2 36.9

40
Te m p. (C )

Reservoir Com position Shut in Com position

30

20

10

0
10.3 11.4 12.5 16.9 18.1 19.2 23.6 24.7 25.8 30.3 31.4 13.6 14.7 15.8 20.3 21.4 22.5 26.9 28.1 29.2 3.6 0.3 1.4 2.5 4.7 5.8 6.9 8.1 9.2

Tim e (H rs)

Pipeline & Riser Slugging

Insufficient gas velocity in riser Liquids accumulate at bottom of riser

Upstream pressure builds sufficiently to overcome hydrostatic head in riser Slug of liquid is expelled, followed by gas which has packed behind blockage

Liquid accumulation at riser base seals off gas flow Flow out of riser stops

Slugging Types: Hydro-dynamic Terrain Riser induced

Liquid continues to accumulate at the riser base Riser begins to fill with liquid Pressure builds upstream of the blockage

FA Consequences of Slugging
Safety to personnel and equipment Unstable production Equipment trips Total field shutdown Loss of revenue e.g. 100mbpd field shutdown: loss of $5m /day @ $50/bbl & $10m @ $100/bbl
Slug Characteristics
700 600 500 400 300 200 100 0
6067 12498 18819 25029 31129 37119 42998 48767 54425 59973 65411

Frequency (1/Hr) Length (m) Volume (m3)

Flow Rate (bbl/d)

Asphaltenes

Polar components in crude oil

Stable in presence of resins Resins diluted by gas release and injection Flocculate in wells and topside equipment Prediction via SARA analysis Saturates, Aromatics, Resins and Asphaltene fluid property analysis. Asphaltene content: amount of material insoluble in n-heptane (or n-pentane) but soluble in toluene

Precipitation is induced by pressure decrease and/or changes in the solvency of crude oil (by low MW n-paraffins, CO2, acids, etc)
Minimum solubility at bubble point

S.L&B.E-2000

Emulsions Consequences
Tight emulsion between water and oil Viscosity at Low Shear Rate (cPoise) causes inversion viscosity 10,000 High pressure drop in pipelines Separation efficiency impaired Shut-in conditions can cause rheology change to Non-Newtonian behaviour High yield stress at low shear rates 100 require very high pressure to start up pipeline.

Shear Stress

5
Non-Newtonian

0
Newtonian

10

20

S-1

Shear Rate

FA Sand Erosion
Consequences:
Sand Erosion (Pipeline Outlet)
Sand Rate kg/month 1 5 10 15 20 50 100 200 300 400 500 1000

Material Loss
Errosion (mm/yr)

0.5 0.45

Pipeline leaks
Separator Efficiency

0.4 0.35 0.3 0.25 0.2 0.15 0.1

12498

18819

25029

31129

37119

42998

48767

54425

59973

Requirement for CRA materials

Flow Rate (bbl/d)

65411

6067

Erosion Velocity Limits

0.05 0

FA Corrosion
Pipeline Corrosion

Issues:
Development of Anti-Corrosion Strategies Integrating MultiPhase Flow
6.0 5.0 4.0 3.0 2.0 1.0 0.0
Corrosion (mm)

Corrosion Rate (mm/year) Corrosion (including fugacity) Corosion (fug+pH) Corrosion (Wcut >5%) Corrosion (90%inhib.eff) Commulative Corrosion

11

13

15

17

Time (Yrs)

19

De-Ward Milliums

Low Temperatures Well Start-Up

Issues:
Prod. Hydrates S/U Material Integrity Prod. Loss System S/D Safety
0 0
0

50 100 150 200 250 300 350 400 Time (s)

-5

-10 Temp. (C) -15

Outlet-Insulated Middle-Insulated Uninsulated Inlet-Insulated

Mitigation: Flowline Insulation Operational

-20 -25

FA Consequences

Incorrect

System designs Un-necessary Operating Problems Potential Flow Path Blockage Resulting Production Shut down Consequential Revenue Loss In the extreme: Loss of Asset.

Flow Assurance Solution Options

Fluids Handling Mix Chemicals Thermodynamic, Kinetic, THI, AA Heat Retention Insulation (Passive) Provide Heating : Fluids / Circulation, Electrical, Other Active Methods Remove Heat Change Rheology (Cold Pipe Slurry) Separate Fluids Re-Combine Fluids Subsea GTLA Others

Enabling Technologies
Subsea Processing Separation Multiphase Pumping Metering Subsea Gas Compression
Tree
Separator/ Boosting

FPSO

Tanker

To FPSO
Coselle s

Multiphase Transport

Gas

Oil Water

Reservoir

Reservoir

Reservoir

Pipeline Thermal Management Raw Sea Water Injection Gas to Liquids Conversion Gas to Liquids Absorption Other Emerging Technologies

Technology- FA Cost Vs Benefit Map

Cost (Capex / Opex / Intervention)
Chemicals Microbes ? Slurry Transport Down Hole Processing (ESP/HSP) Active Heating Electrical Induction Trace Liquid Circulation Subsea Processing

Risk

PIP Draining Systems Pigging Low Cost Insulation Intelligent Slug Control Chemicals Slug Control Multiphase Pumping Liquid Boosting Subsea G-T-L-A

Simplicity

Benefit

What is GTLA ?
Gas to Liquid Absorption. Process of Gas Absorption of C1-C3,, CO2,H2S by high gas solubility liquids. Fluids Phase Equilibrium Change. Recovery of Oil Light End Components (C3-C8). Multiphase to Liquid Only Transport. Considerable Benefits (Capex / Opex). Innovation / Value.

What is GTLA ?
3 Components to GTLA: Subsea Achitecture & Absorption. Transportation. Host Facilities Processing. System configurations Reservoir fluids characteristics.

Hydrate Blockage Risks

Conventional
Production Rates Gas Water

GTLA
Oil

5 Years

10

15

Wax Blockage Risks

Conventional
Production Rates Gas Water

GTLA
Oil

Years

10

15

Marginal Field Development GTLA

Floating Processing

Power/Umbilical

G-T-L-A Absorber

Liquid Pump

No Manifold No Well to Manifold lines No PIP / insulation Single Production Line

Water Injection

Impact of GTLA Technology on Hydrate Dissociation.

Hydrate Envelopes
140

120

Water Temperature 2000m - Angola

100

Pressure (Bara)

80 Normal GTLA 60

40

20

0.01

0.32

1.54

0 -60 -52 -44 -35 -27 -19 -11 -2.3 -0.1

10

12

14

16

18

Temperature (C)

20

GTLA Technology Benefits

Technical
No Slugging No Hydrates or Wax Reduced Corrosion Reduced Scale Reduced pipe wt, expansion & stress, upheaval buckling, expansion joints and burial. Reduced Riser fatigue Increased Safety, Availability, Reliability & Recovery Pressure Boosting via Liquid Pumps.

Economic
One Production Pipeline No Pipeline Insulation No Manifold 60% Pipeline Capex reduction (no insulation and use of CS rather than CRA) Use of SCRs Smaller Umbilical Size No Hydrate or Wax inhibitors Reduced Interventions.

Integated System

Integated System- General Basis

Sizing of Subsea Infrastructure: System Data: Reservoir Pressure = 200bara & Host Pressure = 15bara. Reservoir temperature = 60deg.C. Well Tubing = 5 & 1500m length. Sea bed and sea surface temps. = 5 & 15deg.C. Oil Viscosity = 15, 20 & 30 degrees. Water Depth =100-2000m Tie-back Distance = 10-50km. U = 3W/m2.K Constraints: Erosion Limit = C factor of 150 carbon steel pipe. Hydraulic Limit = Based on max Well Head pressure (150bara)

Integated System Infrastructure

Offshore Host facilities

Onshore Facility

Deep Water Risers

Seabed Wells

Integated System-Charts
12" Multiphase Production-100-2000m Water Depth
140 120 100 80 60 40 20 0
GOR=100 Visc=30 GOR=100 Visc=20 GOR=100 Visc=15

GOR=500 Visc=30
GOR=500 Visc=20 GOR=500 Visc=15 GOR=1000 Visc=30 GOR=1000 Visc=20 GOR=1000 Visc=15 GOR=1500 Visc=30

mbopd

WD=100m D=10km D=20km D=30km D=40km D=50km

WD=500m D=10km D=20km D=30km D=40km D=50km

WD=1000m D=10km D=20km D=30km D=40km D=50km

WD=1500m D=10km D=20km D=30km D=40km D=50km

WD=2000m D=10km D=20km D=30km D=40km D=50km

GOR=1500 Visc=20 GOR=1500 Visc=15

GOR=2000 Visc=30
GOR=2000 Visc=20 GOR=2000 Visc=15

Tie-Back Distance (km)

Integated System-Charts
10" Multiphase Production-100-2000m Water Depth
100 90 80 70 60 50 40 30 20 10 0

GOR=100 Visc=30 GOR=100 Visc=20 GOR=100 Visc=15 GOR=500 Visc=30 GOR=500 Visc=20 GOR=500 Visc=15 GOR=1000 Visc=30 GOR=1000 Visc=20 GOR=1000 Visc=15 GOR=1500 Visc=30 GOR=1500 Visc=20

mbopd

WD=100m D=10km D=20km D=30km D=40km D=50km

WD=500m D=10km D=20km D=30km D=40km D=50km

WD=1000m D=10km D=20km D=30km D=40km D=50km

WD=1500m D=10km D=20km D=30km D=40km D=50km

WD=2000m D=10km D=20km D=30km D=40km D=50km

GOR=1500 Visc=15 GOR=2000 Visc=30 GOR=2000 Visc=20 GOR=2000 Visc=15

Tie-Back Distance (m)

Integated System-Charts
GOR=100 Visc=30

8"Multiphase Production-100-2000m Water Depth

70 60 50

GOR=100 Visc=20 GOR=100 Visc=15 GOR=500 Visc=30 GOR=500 Visc=20 GOR=500 Visc=15 GOR=1000 Visc=30 GOR=1000 Visc=20

mbopd

40 30 20 10
WD=100m D=10km D=20km D=30km D=40km D=50km WD=500m D=10km D=20km D=30km D=40km D=50km WD=1000m D=10km D=20km D=30km D=40km D=50km WD=1500m D=10km D=20km D=30km D=40km D=50km WD=2000m D=10km D=20km D=30km D=40km D=50km

GOR=1000 Visc=15 GOR=1500 Visc=30 GOR=1500 Visc=20 GOR=1500 Visc=15 GOR=2000 Visc=30 GOR=2000 Visc=20 GOR=2000 Visc=15 GOR=2000 Visc=15

Tie-Back Distance (km)

Integated System-3D Chart

Integated System-3D Chart

Flow Assurance Technology Options & Pipe Sizing for DeepWater & Long Distance Oil & Gas Transport.Transport Requires:
Innovative Flow Assurance Solutions Better use of existing & New Technologies Overcoming Fear to Change Offer Value Added Benefits Low Risks Cost of Change

Beware: Operators are queuing up to be 2nd or 3rd to use new technology.

Opportunity to Change

Exploration

Appraisal / FEED

Detailed Design

Operations

I would be happy to answer any easy questions

Cost of Change

Thank You

Opportunity to Change

Exploration

Appraisal / FEED

Detailed Design

Operations