SPE

Society of Petroleum Engineers

SPE 23090

New Water Injection Technology

a.F. Graff, Aker Engineering a.s, and N. Nielsen, Saga Petroleum a.s

Copyright 1991, Society of Petroleum Engineers, Inc.

This paper was prepared for presentation at the Offshore Europe Conference held in Aberdeen, 3-6 September 1991.

This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract sUb~itted by the author(s). Contents of t~e paper,
as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correctio~ by the aut~or(s). The ma~erlal, as presen~ed~ does not necessarily ref~ect
any position of the Society of Petroleum Engineers, its officers, or members. Papers presented at SPE meetmgs are subject to publication review by Editorial Committees of the SOCiety
of Petroleum Engineers. Permission to copy is restricted to an abstract of not more than 300 words. Illustrations may not be copied. The abstract should contain conspicuous acknowledgment
of where and by whom the paper is presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836 U.S.A. Telex, 730989 SPEDAL.

ABSTRACT INTRODUCTION
Water injection facilities are now used more Seawater is a complex fl uid both from a chemi ca1
frequently on offshore platforms to maintain and biological viewpoint. The chemical and
reservoir pressure and hence maintain the oil biological analysis of seawater are dependant on
production capacity and increase oil recovery. The location and waterdepth and varies during the
injection of large amounts of treated seawater at seasons. The seawater which is injected into the
high pressure into the reservoir traditionally oil reservoir requires special treatment. The
reqUires considerable equipment space and power. des i gn requi rements for a water i njecti on plant
The system operating weight will also be high. depend on the type of oil reservoir and the
planned production profiles and oil recovery. The
The development of new fields at increasing water normal treatment of the seawater can be summarised
depths has encouraged the use of new technology. as follows:
The development of topside systems with high
efficiency and 1ight weight is thus a challenge Sterilising is used to stop the organic
for platform des i gners and equ i pment supp1i ers . activity.
The water injection system for the Snorre TLP
represents a significant advance in the system Fi ltrat i on reduces the foul i ng and prevents
design, resulting in considerable space savings possible plugging of reservoir.
and a weight saving of about 560 tonnes.
Oxygen removal will prohibit organic activity
The Snorre Water Injection Facil i ty is the fi rst and corrosion.
of a new generation of systems. Cartridge filters
which are cleaned by means of sulphuric acid are Chemica.l additives are often used for
used for fine filtration of the seawater. The improved operation of treatment equipment.
deoxygenation of the seawater is carried out in a
two stage nitrogen stripping unit, reducing the A traditional water injection system comprises the
oxygen content to below 10 ppb without chemical following main equipment units:
additives. Vertical injection pumps were also
selected eliminating the traditional booster pumps Dual media filters for fine filtration of the
and lube oil system. A full scale test of this seawater.
unique system was carried out in the summer 1990.
Test results showed that all parts of the system Deoxygenation of seawater in a vacuum or gas
were operating satisfactorily and within the stripping tower.
design specification.
Booster and horizontal main injection pumps.
The conventional system design contributes
considerably to the topside space and weight and
requires modification for operation on a floating
production unit.

521
2 NEW WATER INJECTION TECHNOLOGY
SNORRE WATER INJECTION FACILITY
The Snorre tension leg platform (TLP) will be the
first North Sea installation deployed in water
depths greater than 300 m (Block 34/7 in the
Norwegian Sector). The planned production start is
October 1992.
The selected platform concept was a technical
cha11 enge wh i ch encouraged the use of new
technology to achieve a reduction in topside
weight and space requirements. The operability of
alternative systems during platform movements was
also evaluated. .
The Snorre Water Inject ion Facil ity is the best
example where new technology was used in the
system design. The sel ected system differs
considerably from a conventional facility. This
paper gi ves a bri ef descri pt i on of the Snorre
system which is the first of a new generation of
water inject i on systems offeri ng several
advantages.
Approximately 560 tonnes has been saved compared
to more convent i ona 1 systems. Recent technology
and an efficient engineering have made it possible
to include the entire system on a compact
prefabricated deck section, D21 shown in Figure 1.
This allows full commissioning and operational
testing prior to 1 ifting the facil ity into the
deck.
The D21 mainly comprises the water injection
system with the following key data:
Length 22.75 m
Height 14.50 m
Width 20.00 m
Operating Weight 760 tonnes
Dry Weight 650 tonnes
A schematic block diagram of the Snorre Water
Injection System is shown in Figure 2. The
facil ity can supply up to 60.000 cubic meter of
injection water per day at 220 barg. The oxygen is
removed to a level below 10 ppb and 98% of all
particles larger than 2 microns are filtered out.
The injection water specification is reached
without the use of any chemical additives. The
system is not sensitive to platform motions.
Cartridge filters are used for the fine filtration
of the water. The filters are cleaned by means of
sulphuric acid removing the organic matters
trapped in the fil ter. The deoxygenat ion of the
seawater is carried out in a two stage nitrogen
stripping unit. Oxygen rich nitrogen is reclaimed
over a palladium catalyst and recirculated. The
treated water is injected to the reservoir by
vertical pumps eliminating the traditional booster
pumps.
Fine Filtration
A schematic diagram of the Fine Filtration System
is shown in Figure 3.
522
SPE 23090
Seawater for the water inject ion system is taken
from the seawater distribution system after it has
passed through the coarse filters (98% removal of
particles above 100 microns) and the cooling
medium coolers. The warm seawater (minimum 12°C)
is routed to the Fine Filter Package.
The fil ter package consi sts of 7 fi lter vessel s
each with a capacity of 16.7% of the design flow.
Thus 6 vessels will handle the maximum design
flow. One vessel provides the stand-by capacity,
when the other vessels (one at a time) are being
backwashed.
Filtration takes place by passage of water through
the pure polypropyl ene fil ter cartridges wi th an
absolute pore size rating. The filtration is
carri ed out in two stages, both mounted in the
same vessel. The first stage contains 214 filter
elements with a relatively large pore size (40
microns). The second stage contains 223 elements
with a smaller pore size (10 microns). The
specification of the seawater (98% removal of all
particles above 2 microns) is met after passing
through both stages.
The initial pressure drop across the filter
vessels is about 0.1 bar. The reconditioning
sequence is initiated when a setpoint of 3.5 bar
differential pressure across the filter vessel is
reached or when a predetermined amount of time has
elapsed which ever is first.
Restoration of the initial pressure drop is made
possible through appl ication of concentrated
sulphuric acid to the adhesive layer of organic
particles. A dehydration reaction will then take
place, which converts the organic materials to
carbon and water:
exothermic
-----------> 12 C + 11 H20 (1)
H S0
2 4
The speed of the dehydration process depends on
the acid concentration. Increased concentration
reduces the required reaction time. Acid
concentration in the filter media is maximised by
removal of excess water in the filter cartridges
prior to acid application. Therefore the filter is
first drained, followed by an air purging process
where pressurised air is introduced into the
vessel to remove most of the water from the filter
elements.
A pre-determined amount of acid (30 litre) is
pumped into the foam generator which is
subsequently mixed with air from the air receiver.
The pressurised air transforms the 1iquid into a
mist and transports it into the filter vessel. The
only way out is thus through the filter cartridges
which will capture the fine droplets of acid. The
air and any entrained acid droplets are removed in
the gas cyclone downstream of the filters.
SPE 23090 O.F. GRAFF AND N. NIELSEN
An even distribution to each cartridge is obtained
through an acid distributor, located above each
filter stage. The acid mist is distributed to each
stage in separate sequences. When sufficient
reaction time has passed, the filter vessel is
filled with water and drained twice. The acid
concentration in the first flushing will be 2-3%.
The durat i on of the complete recond it ion i ng
sequence is approximately one hour per filter
vessel.
The main advantage with this fine filter system
compared wi th a convent i ona1 sand fi lter system,
is the space and weight savings. The approximate
equipment weight saving is in the order of 250-300
tonnes. The use of cartridge filters eliminates
the use of polyelectrolyte or other filter
chemical aid. However, the disadvantage is the
annual use of about 50 cubic meters of sulphuric
acid for filter cleaning.
Operational experience with some sand filter
systems show loss of sand in the filters. The sand
follows the seawater to the injection pumps which
are thereby eroded. This problem is completely
eliminated by the use of cartridge filters.
Deoxygenation
A schematic diagram of the Deoxygenation System is
shown in Figure 4.
The seawater from the fi ne fi 1ters is routed to
the next treatment stage, the deoxygenation. The
oxygen 1eve1 in the seawater is reduced below 10
ppb ina two stage stri ppi ng process without use
of chemical additives.
The system utilises the same principle as in
conventional gas stripping towers, but in a
different way.
The mass transfer unit comprises of two stages in
a series of vertical "serpentine" stripping tubes
(U-tubes) termi nat i ng at a hori zonta1 gas water
separator. The flow regime in the serpentine tubes
will determine the rate of mass transfer. The
transfer of oxygen to nitrogen is mainly carried
out in the upward co-current flow of seawater and
nitrogen.
The filtered seawater passes the first stage
"serpent i ne" tube and the fi rst stage separator
operating at 0.2 barg. The seawater is boosted by
3 x 33 1/3% interstage pumps before entering the
second stage "serpentine" tube and separator
operating at about 1.5 barg.
The nitrogen (including some oxygen) which is
liberated from the second stage separator is
injected into the fi rst serpentine section. The
nitrogen (including more oxygen) from the first
stage separator flows to a set of 3 x 33 1/3%
compressors. The gases from the compressors are
discharged into a catalyst reactor after methanol
has been injected into the inlet line.
523
3
Palladium is used as catalyst and the following
reaction occurs:
exothermic
3 O2 + 2 CH 3 OH > 2 CO 2 + 4H 20 (2)
The methanol reacts wi th oxygen to form carbon
dioxide and water and these together with the
inert nitrogen gas are discharged from the reactor
and re-injection into the second stage stripping
tube.
The main advantage with this system is the weight
and space savings. Compared to a conventional
deaerator tower, approximately 100 tonnes were
saved. The oxygen 1eve1 in the seawater is met
without use of scavenger in this system. Another
ach i evement wi th the Snorre Deoxygenat ion System
is that the nitrogen is recycled in a closed loop.
Other conventional gas stripping systems use
nitrogen or fuel gas which is not regenerated
(waste). Other vacuum systems require maintenance
and inspection to avoid leakage and ingress of air
(oxygen). The Snorre system operates at pos it i ve
pressures and ingress of air is thereby avoided.
Water Injection Pumps
The water injection pump station comprises 4 x 25%
Water Injection Main Pumps and 1 x 100% Water
Injection Topping Up Pump. Each main pump has a
design capacity of 625 m3 /h and takes suction from
the 2nd stage gas water separator in the
deoxygenation package. The pressure is raised to
219 barg for injection into the platform wells.
The topping up pump with a design capacity of 600
m3 /h increases the pressure by 32 bars from the
main pumps discharge for injection into the
furthest subsea wells.
Two significant contributions to the remainder of
the weight/space savings were achieved for the
pump station:
1. Introduction of vertical pumps
2. Elimination of conventional booster pumps
upstream of the main pumps as a combi ned
result of higher pressures downstream of the
deoxygenation package and reduced suction
pressure demand for the main pumps.
This in turn led to a considerable saving in deck
space together with the above mentioned
achievements which resulted in leaving out one
intermediate deck level in this area of the
topsides.
Pumps installed with their impellers and
electrical drivers in a vertical stack mode were
compared to the conventional horizontal
arrangement wi th the motor mounted next to the
pump. The vertical arrangement was applied for all
water injection pumps. The result for each main
pump was a 6.3 meters high unit including a motor
of 5000 kW as shown in Figure 5.
4 NEW WATER INJECTION TECHNOLOGY SPE 23090

The fo11 owi ng relevant features were taken into CONCLUSIONS

account in the design:
1. Water injection facilities are becoming more
Only one sixth of the area is used compared important for maintaining the reservoir
with traditional horizontal arrangement. The pressure and thereby the oil production
increased height requirement was available capacity and recovery.
without any increase of the deck height.
2. The injection of 1arge amount of treated
The reduction in weight was significant as seawater at high pressure, will require
reduction was achieved due to simpler considerable equipment space and power. The
foundations, al ignment arrangements, simpler operating weight will also be high.
pump internals .and no requirement for
external lube oil system. 3. The search for new technology which will
reduce the overall cost of the water
The vert ica1 sol ut ion requ i res no ali gnment injection systems will result in a new
between the pump and the motor, thus generation of systems.
simplifying the installation and maintenance
operations. 4. The Snorre Water Injection Facility will be
the fi rst of thi s new generation. The
The electrical motor has to be removed when facility represents a significant advance in
work is carried out on the pump internals. the system design, resulting in considerable
This negative feature has been reduced by space savings and a weight saving about 560
i nsta11 i ng an overhead crane as an integral tonnes.
part of the deck structure.
5. 98% of all particles larger than 2 microns
With regard to operational cost, a saving is are removed in cartridge filters without use
expected due to the simpler internal arrangement of filter chemical aid.
of the pump and no need for al ignment between
pumps and motors after maintenance. 6. The oxygen content is reduced to a level
below 10 ppb without use of chemical
Performance Test additives.
A full scale test of the Snorre Water Injection 7. Vertical injection pumps have been
Facil ity was carried out in June/July 1990. The successfully tested. The vertical arrangement
prefabricated deck section (021) was placed on a has several advantages.
barge at a yard in Egersund, Norway. The Snorre
TLP Main Generators were used as power supply. 8. A full scale test of this unique system was
Temporary systems for the seawater supply and carried out in the summer 1990. The result
return were made for the test. A temporary control showed that all parts of the system were
room was also provided. operating satisfactorily and according to the
design specifications. The system will be in
The main purpose of the test was to verify this operation from October 1992.
unique system design. Two important tasks were
identified for this test:
Check performance of each unit/package
Tune and verify the overall control system.
Several test runs were carried out monitoring the
following parameters:
Filtration efficiency of cartridge filters.
Effect of filter regeneration (sulphuric
acid).
Oxygen and chlorine level in treated
seawater.
Vertical pump performance.
Vibrations of equipment and pipework.
Stability and response of control system.
Corrosion rates.
The results from the test show that all systems
were operating in a satisfactory manner. However,
some mi nor modifi cat ions wi 11 be eval uated based
on the test runs, in order to improve the overall
performance of the system.

524
 S~E 23090

OTHER
SEAWATER
USERS

SEAWATER COOLIN G
COARSE MEDIUM
FILTERS COOLERS

~~~~~:ER I:~~~~IONI ~l ~I~~~~~ON

SEAWATER
SEAWATER
SEAWATER ILiFT RETURN i i
RETUR N PUMPS PUMPS

SEAWATER
RETURN

Figure 2

Block Diagram - Snorre Water Injection System

~
Ul

AIR
AIR RECEIVER
FILTERED SEAWATER

VENT

Figure 1 DRAIN

FILTER
SEAWATER
3D-model of D21 - Snorre Water Injection Facility VESSEL

FOAM
GENERATOR
SULPHURIC ACI D

Figure 3

Schematic Diagram - Fine Filtration System

 seE 23090

AJR/NZ

r-----=Nl--:_-~-------_--. .------l
. SERPENTINE

----------------T----.·
r-----l
I I
I
I
I
SEAWAT E R .,_.L---tiilit---K'" I

I
j
RECYCLE METHANOL
COOLER

CATALYST
REACTOR
COMPRESSORS SEAWATER
RETURN
( SCAVENGER)

DRAIN
FRESHWATER

Figure 4

Schematic Diagram - Deoxygenation System

Figure 5

Vertical Mounted Injection Pump

526