THERMAL INSULATION DESIGN OF EGINA

SUBSEA PRODUCTION SYSTEM

Sunday OMOWUNMI - TEP Nigeria / EGINA Project
Julien ROLLAND - DEV/ED/ECP
CONTENTS

● Egina hydrate prevention philosophy

● SPS cooldown requirements

● Thermal analysis methodology

● Thermal analysis results

● Cooldown test results

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EGINA HYDRATE PREVENTION PHILOSOPHY

● Normal operation shall be outside hydrate formation zone.

● Thermal insulation of subsea equipment shall give required
cooldown time during shutdown (GS EP SPS 008).
● Hydrate inhibition by chemical injection during start up in early –
mid life.
- MeOH injection at the Xmas tree
- LDHI-AA injection at the manifold

● Hot dead oil re-circulation to warm up production loop during very

high WC in later life.
● Subsea preservation during shutdown.
- MeOH flushing of tubing, jumper and gas lift riser
- Dead oil circulation of production loop

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 HYDRATE RISK - CONDITIONS DURING SU/SD

● Start up
- Cold restart: T ~ 4oC
- Aborted start up: 4 < T < 35 oC
- Warm restart: T > 35 oC Hydrate
zone!!!

● Shut down No risk of

Hydrate
- Long shut down: T ~ 4 oC Start up

- Short shut down: T > 35oC

Shut down

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 SPS COOLDOWN REQUIREMENTS

● Xmas Tree Cooldown

requirement. XTree
Manifold
- 40 down to 23 °C in 8 hrs U/S Jumper

PWV MPP

- 40 down to 20 °C in 8 hrs D/S

OHTC [W/m2/K]
PWV PWV: Production Wing Valve

Girassol Dalia Rosa Moho Akpo Pazflor Usan Clov Girri Moho Moho Egina Kaombo
Bilondo 1bis North

● Challenges Fluid in
- Low Wellhead temperature
- Cold spots (valves, sensors,
injection points etc)

Cold wells (WHFT 32 oC) to be preserved in priority during production shutdown

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 MANIFOLD COOLDOWN REQUIREMENTS

● Manifold Cooldown requirement

- Deadleg to be above 20 oC in Steady State
- X – 20 oC in 8 hrs in header and branch
deadleg
- 40 – 20 oC in 13 hrs elsewhere

● Challenges
- Low Wellhead temperature
- Cold spots (valves, sensors, injection
injection points etc)
- Long deadleg due to six-slot configuration

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THERMAL ANALYSIS METHODOLOGY

There are 3 Phases:

● Phase 1: Calibration of analysis methodology by FEA/CFD modelling

and Pilot cooldown test.

● Phase 2: Thermal insulation design by thermal analysis for each

subsea equipment, subsystems and systems in order to meet the
cooldown requirement.

● Phase 3: Thermal analyses of actual “test setup” to verify insulation

design by comparing results from modelling and Cool down test.

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THERMAL ANALYSIS METHODOLOGY (PHASE 1)
Estimation of thermal input parameters for FEA
Artificial thermal conductivity, Keff
Convective Conductive

External Heat transfer coefficient, eHTC

AND

Churchill-Bernstein, forced convection

Internal Heat transfer coefficient, iHTC

Churchill and Chu, free convection (Cooldown)

Other iHTC correlations for forced convection (Steady state)

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THERMAL ANALYSIS METHODOLOGY (PHASE 1)

Internal Heat transfer coefficient, iHTC

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 XMAS TREE - FEA SET UP (PHASE 2)
Project Rosa Moho Clov Egina
Insulation thickness (inches) 3 NA 3 1/4 4 1/4

Insulation volume (liters) 2,200 3,500 4,700 5,600

Isometric view with insulation Cross sectional view Isometric view without insulation

PSV Cavity
(ref. only)

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XMAS TREE - FEA RESULTS (PHASE 2)
Gas initially at 40 oC

23 oC
20 oC

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MANIFOLD DEAD LEG CFD RESULTS (PHASE 2)
Gas initially at 40 oC – temperature after 8 hrs of Cooldown
● Bulk temperature in header (volume average) of 22 oC.
● Coldest location 14.7 oC - at wall of gate valve in shut-in position.

Coldest location in
contact with live fluid

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MANIFOLD DEAD LEG CFD RESULTS (PHASE 2)

Oil initially at 40 oC – temperature after 8 hrs of Cooldown

● Bulk temperature (volume average) of 28 oC.
● Coldest location 13.5 oC - at wall of gate valve in shut-in position.

Coldest location in
contact with live fluid

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 MANIFOLD DEAD LEG CFD RESULTS (PHASE 2)
Coldest Location on Gate Valve

Egina Gas Egina Oil Unit

Momentum diffusivity, n = µ/r 1.6E-07 1.1E-05 m2/s

Thermal diffusivity, a = k /r Cp 1.6E-07 7.6E-08 m2/s

Pr indicates the relative thickness of
Prandtl number, n /a = µCp/k 1.0 144.5 momentum and thermal boundary layers

Gas Oil

14.7 oC 13.5 oC

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COOLDOWN TEST (PHASE 3)
Cooldown tests scheduled between 2014 and 2016

Subsystem / System CDT Part of (System) Location Status

Gate valve Manifold branch Norway Completed
Ball valve Manifold header Norway Completed
Connectors XT and Manifold Norway Pending
MPFM Manifold Norway Pending
Choke Valve XT Norway Pending
Manifold header dead leg Manifold Norway Pending
XT System Norway Pending
Manifold System Nigeria Pending

Test site
Test tank

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COOLDOWN TEST RESULT (PHASE 3)
5 1/8” Manifold Gate Valve
Test set up
Valve actuator
piping
Valve body

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WAY FORWARD – HYDRATE RISK ASSESSMENT

● Impact of geometry and phase segregation.

● Design criteria vs actual field conditions.

- Evolution of Well head temperature and pressure as watercut increases

● Stoichiometry of stagnant phases.

- Water/gas ratio required to form hydrate plug (watercut, GOR)

● Propensity of Egina crude to form hydrate.

- Lab test at different subcooling

● Operator guide manual for proper risk assessment

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 Bedankt
gracias Terima Kasih
Cám ơn
谢谢
Thank you

merci
спасибо

Obrigado
‫ﺷﻛﺭﺍ‬
Tusen takk
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BACK-UP

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EGINA HYDRATE CURVE

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 SPS COOLDOWN REQUIREMENTS

Xmas Tree Cooldown requirement

● 40 (32) – 23 oC in 8 hrs U/S PWV
● 40 (32) – 20 oC in 8 hrs D/S PWV

Challenges
● Low Wellhead temperature
● Many cold spots (valves, sensors, choke etc)

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XMAS TREE FEA RESULTS
Gas initially at 32 oC and 0.25 m/s after 8 hrs of cooldown

Cold wells (WHFT 32 oC) to be preserved in priority during production

shutdown

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WELLHEAD FLOWING TEMPERATURES
Temperature {oC} Temperature {oC}
# Well # Well
Min Max Average Min Max Average
1 A_P1 33.0 47.4 40.2 12
C_P2 61.6 71.2 66.4
2 A_P3 34.7 48.6 41.7 46.0 13 58.8
B_P2 50.4 60.6 55.5
3 B_22 53.1 58.9 56.0 14
B_P3 52.7 60.2 56.5

4 A_P2 44.7 48.3 46.5 15 B_P4 52.3 59.2 55.8

49.3
5 A_P5 43.3 47.6 45.5 16 B_P5 56.2 59.1 57.7
58.6
6 BP_10 51.8 60.1 56.0 17 B_P9 56.6 57.8 57.2

7 A_P2B 42.9 47.7 45.3 18 C_P1 57.6 69.9 63.8

8 B_P7 51.1 55.9 53.5 19 B_P7B 52.9 55.3 54.1

52.7
52.3
9 B_P6E 45.9 59.8 52.9 20 B_P6D 45.2 58.6 51.9

10 B_P12 57.4 61.2 59.3 21 B_P8 46.5 55.2 50.9

11 B_P1 53.5 60.5 57.0

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WELLHEAD FLOWING PRESSURES

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 MANIFOLD GATE VALVE

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XMAS TREE MASTER VALVE

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XMAS TREE – BOUNDARY CONDITIONS (PHASE 2)

Well CFD Well CFD

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HEAT TRANSFER FUNDAMENTALS

r3

r2Heat transfer principles

Conduction r1
Forced convection
Free convection

Methods
Analytical
Numerical
FEA
CFD
Test

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