Exploiting Oil & Gas Fields

Flow Assurance for Offshore Oil & Gas Production?

Training Course
PetroEdge: 25 July-29 July 2011
Kuala Lumpur

Dr. Kashmir Johal

Director- FIM

www.Fluidsinmotion.com
 Agenda
Day 1:- The Big Picture
Introductions / Safety
• Industry Outlook
• Reservoirs
• Fluids Transportation
Tea Break
• Host Facilities
• Development Costs
• Summary of FA Issues
• Opportunities for New Technologies
Lunch
• Start of Design Workshop
• Selection of Fields & Groups
• Design of Pipelines &Risers
• Insulation Requirements
• Chemicals
• Other Technologies
 Agenda
Day 2:- Flow Assurance Considerations
• Multiphase Thermo-hydraulics
• Slugging
• Hydrates
• Wax
• Asphaltenes
Tea Break
• Scales
• Erosion
• Corrosion
• Chemical Inhibitors
Lunch
• Workshop Continuation
• Development of Flow Assurance Strategies
 Agenda
Day 3:- Enabling / Emerging Technologies
• Flow Assurance Solutions
• Subsea Processing
• Separation
• Multiphase Pumping
• Metering
• Subsea Gas Compression
Tea Break
• Pipeline Thermal Management
• Raw Sea Water Injection
• Gas to Liquids Conversion
• Gas to Liquids Absorption
• Other Emerging Technologies
Lunch
• Workshop Continuation
• Selection of Best Technologies for Field Type
• Analysis of Technologies
• Risks in use of Technologies
 Agenda
Day 4:- Workshop Conclusion

• Surge
• Software Solutions- Field Options
Tea Break
• Results of Workshop
• Group A: Deep Water Oil Field Presentation
• Long distance Oil field tie-back to Platform
Lunch
• Group B: Long Distance Gas Condensate Field Presentation
• Open Forum & Additional Cases
• Workshop Conclusion
 Agenda
Day 5:- Training Conclusion

• Deep Water Workshop Solution

• Summary of Flow Assurance Issues
• Summary of Flow Assurance Technologies
Tea Break
• Open Discussion Forum
• Award of Certificates
• Training Conclusion
Lunch
• Meetings with Attendees as Required.
 Industry Outlook

Big Picture
• Exploration / Drilling

• Reservoir / Field

• Wells

• Transportation

• Host Facilities

• Product to Market

• Costs & Oil Price, Marginal Fields, Political Aspects

 Industry Outlook

World Energy Supply

Potential Future Oil & Gas Scenarios

Million Barrels per Day

Gas Exploitation

70

Enhanced Recovery

Existing Fields

Existing Production

2000 2010 2020 2030 2040

0 0 0 0 0

Years
 Industry Outlook

World Energy Supply-Growing Gap

Million Barrels per Day

Growing Gap

Future Demand

70

Oil Production

2000 2010 2020 2030 2040

0 0 0 0 0

Years
 Industry Outlook

Asia Pacific Proven Reserves

 Industry Outlook

Asia Pacific Proven Reserves

 Industry Outlook

Malaysia:
 Industry Outlook

Malaysia:
 Industry Outlook

Stranded Gas:
Tonnes/Yr)

Pipeline Transport
Gas Production (M Ton

LNG Transport

CNG Transport

STRANDED GAS

Distance to Market
 Reservoirs

Reservoir Discovery:
• Field Appraisal Areal Extent Gas Cap
• Size Layer Discovery
of Well
Well
• Production Method
• Economically Viable
• Seismic Surveys
• 3D Image
• Appraisal Wells
• Size and Structure of field
• Wireline Logging
• Porosity, Fluid Saturation &
Thickness
Dry Well &
• Well Tests Limit of layer
• Hydrocarbon Samples, Thickness
Reservoir productivity,
Temperature & Pressure
• Existence of
an Aquifer
 Reservoirs

Reservoir Discovery:
• Anticlines- targets for onshore
oil finds

Shale Seal

Cap Gas
Gas

Oil
Oil

Water Water
Shale Seal
 Reservoirs

Reservoir Discovery:
• Traps and Faults

Impermeable Rock

Gas

Oil

Water
 Reservoirs

Reservoir Rock
Samples:
• Laboratory Analysis
• Faults in reservoir &
Poor Porosity Rock (Pour Space- Usually water.)

• Variations in Rock (Sand Grains, Fossils etc.)

Porosity &
Permeability
• Develop Geological
Models Rock (Cement from
• Identification of Precipitated Minerals.)

Micro Fossils
• Best Sites for Rock (Cement from
Production Wells Precipitated Minerals.)
 Reservoirs

Logging Samples:

Rock Type Identification (API Number )

Rock Porosity (%)

Rock Permeability (Mili Darcies)

 Reservoirs

Seismic Surveys:

Tail Buoy
Seismic Survey Vessel
Hydrophone Streamer

Air Gun

Sea

Sound Waves

Rock Strata

Reflected
Sound Waves
 Reservoirs

Drilling
Operations:
Oil Rig Systems
Once the equipment is at the site, the
Derrick
crew sets the rig up. The major systems
of a land oil rig:
Power system
• large diesel engines - burn diesel- Turn Table Engine

fuel oil to provide the main source of Turn Table

Spare Pipe Electric
power
Generator
• electrical generators - powered by
the diesel engines to provide Mud & Casing
electrical power
• Mechanical system - driven
by electric motors
– hoisting system - used for Blow Out
lifting heavy loads; consists of Preventer
Casing
a mechanical winch
(drawworks) with a large steel
cable spool, a block-and-tackle
pulley and a receiving storage Drill Collar Drill String
reel for the cable
– turntable - part of the drilling Bit
apparatus
 Reservoirs-Drilling Operations
Rotating equipment - used for
rotary drilling
• swivel - large handle that holds
the weight of the drill string; allows
the string to rotate and makes a
pressure-tight seal on the hole
• kelly - four- or six-sided pipe that Derrick
transfers rotary motion to the
turntable and drill string
• turntable or rotary table - drives
the rotating motion using power Turn Table Engine

from electric motors Turn Table

Spare Pipe Electric
• drill string - consists of drill Generator
pipe (connected sections of about
30 feet (10 meters) and drill Mud & Casing
collars (larger diameter, heavier
pipe that fits around the drill pipe
and places weight on the drill bit)
• drill bit(s) - end of the drill that Blow Out
actually cuts up the rock; comes in Preventer
many shapes and materials Casing
(tungsten carbide steel, diamond)
that are specialized for various
drilling tasks and rock formations Drill Collar Drill String

Bit
 Reservoirs-Drilling

Casing - large-diameter concrete pipe

that lines the drill hole, prevents the hole
from collapsing, and allows drilling mud to
circulate Mud circulation in the hole
Circulation system - pumps drilling
mud (mixture of water, clay, weighting
material and chemicals, used to lift rock
Derrick
cuttings from the drill bit to the surface)
under pressure through the kelly, rotary
table, drill pipes and drill collars
pump - sucks mud from the mud pits and Turn Table Engine
pumps it to the drilling apparatus Turn Table
Spare Pipe Electric
pipes and hoses - connects pump to
Generator
drilling apparatus
mud-return line - returns mud from the Mud & Casing
hole
shale shaker - shaker/sieve that
separates rock cuttings from the mud
shale slide - conveys cuttings to the Blow Out
reserve pit Preventer
Casing
reserve pit - collects rock cuttings
separated from the mud
mud pits - where drilling mud is mixed Drill Collar Drill String
and recycled
mud-mixing hopper - where new mud is
Bit
mixed and then sent to the mud pits
 Reservoirs-Drilling

• Derrick - support
structure that holds the
drilling apparatus; tall
enough to allow new
sections of drill pipe to be
added to the drilling Derrick
apparatus as drilling
progresses
• Blowout preventer - Turn Table Engine

high-pressure valves Turn Table

Spare Pipe Electric
(located under the land Generator
rig or on the sea floor)
that seal the high- Mud & Casing

pressure drill lines and

relieve pressure when
necessary to prevent a
Blow Out
blowout (uncontrolled Preventer
gush of gas or oil to the Casing
surface, often associated
with fire)
Drill Collar Drill String

Bit
 Reservoirs

Production
Wells
• Number
Production Wells
• Areal Extent
• Depth
Deviated Smart Verticle
• Vertical or
Deviated, Smart
• Production
Capacity
• Oil or Gas
Dominated
• Cost
 Reservoirs

Estimating
Recoverable
Pressure =1Bara
Reserves Production Vessel Temperature = 15deg.C
• Reservoir
Dimensions
• Pressure
• Hydrocarbon Type Verticle
• Development Plan Deviated
• 10-70% Oil
• 85% Gas
• Each Reservoir is
Smart
Unique
• Computer
Simulation Models
• Development Costs
• Price of Oil
• Inflation
• Government-
Approval &
Monitoring Pressure =200Bara
Temperature = 50deg.C
Pressure =400Bara
Temperature =150deg.C
 Reservoirs

Estimating
Quantity Of Oil
Pressure =1Bara
• Reservoir Production Vessel Temperature = 15deg.C
Volume
• Pore Space
Volume Deviated Verticle

Smart

Pressure =200Bara
Temperature = 50deg.C
Pressure =400Bara
Temperature =150deg.C
 Reservoirs
OFFSHORE PRODUCTION OPERATIONS
ISSUES ACCIDENTS
• Marine • Oil spills
Discharges • Chemical spills
• Atmospheric
• Gas releases
• Discharges
• Dropped
• Waste for objects
Disposal on land • Collisions
• Input Overboard Discharge
• Accidental
TREATMENT &
COMPRESSION

Gas to liquids EXPORT

TANKER
TREATMENT SEPARATION
Oil & PIPELINE
Condensate
DRILLING
 Subsea Production System

Production
Tree

Production
Production Jumpers
Tree

Manifold Production
Production Tree
Tree Connectors

Figure 8.7a: Subsea Configuration Showing Trees, Connectors and Jumpers.

 Subsea Production System

Tree Cap

XOV
ASV PSV
P&T P&T

A-Choke P-Choke
AWV PWV
P&T PMV P&T

AMV MV1
MV2
MV3

AMV- Annulus Master Valve DHSV- Down Hole Safety Valve

AWV- Annulus Wing Valve
ASV- Annulus Swab Valve
P&T- Pressure & Temperature
Transmitters
DHSV
P&T PMV- Production Master Valve
PWV- Production Wing Valve
PSV- Production Swab Valve
Well XOV- Cross Over Valve
MV1- Methanol Injection Valves

Figure 8.6: Typical Production Tree .

Subsea Production System

Figure 8.7: Vertical Connection

System.
Subsea Production System

Production Well 1:
Production Well 2:
Choke, Valves, Pressure &
Choke, Valves, Pressure &
Temperature Transmitters
Temperature Transmitters
& Flow Meters
& Flow Meters

Methanol Lines Umbilical

Service Lines

Production Lines

Production Well 3: Production Well 4:

Choke, Valves, Pressure & Choke, Valves, Pressure &

Temperature Transmitters Temperature Transmitters
& Flow Meters & Flow Meters

Figure 8.8: A Typical Subsea 4 Well Slot Manifold.

 Host Facilities-Conventional
Shallow Water Platform

• Water Depth
• Reservoir Size
• Location
• Local Infrastructure
• Production
Capacity
• Cost of Facility
 Host Facilities-Vertically Moored
Tensioned Platform
Host Facilities
• Water Depth
• Reservoir Size
• Location
• Local Infrastructure
• Production Capacity
• Cost of Facility
Host Facilities-Compliant Tower
Host Facilities-Spar Platform
Host Facilities-FPSO Vessel
Host Facilities-Risers

SEA SURFACE

Tensioned
Tendons

Top Tensioned
Risers

Piled
Secured
Templates

Sea bed
Surface

Figure 8.10: Top-Tensioned Risers.

Host Facilities-Risers

SEA SURFACE

COMPLAINT

HYBRID

TOWER

CATINARY

Figure 8.9: Multiple Riser Configurations

 Transportation

Pipelines-Typical U Values
U Value
(W/m2K) Water Depth

LDPU Foam
0.3-2 HDPU Foam
<1500
0.3-2 <2500 GSPU/SPU Wet Insulation
2-10
<3000 Single Pipe in Pipe
1.- 5 <200 Bundle Pipe in a Steel Carrier
0.3-2 <100

<150
<120
<120
<150
<150

Temperature
Lay Method
 Transportation

Pipelines – Insulation Characteristics

K Value
(W/mK) Water Absorption

Polypropylene Reinforced Foam Combination

n/a Polyurethene Reinforced Foam Combination

<5% Phenol Syntactic

n/a Epoxy Syntactic

n/a Epoxy Syntactic with Mini Spheres
<0.5%

Temperature
Density (kg/m3)
 Transportation

LOGSTOR:
Single pipe using PU foam and a HDPE jacket.

U-value: 1W/m²K to 5W/m²K.

Temperature up to 120°C.
 Transportation

Insulation with Phase Change Material

Outer Pipe

Izoflex
Liner

Phase
Change
Inner Pipe
Material
Production
Fluid
 Transportation

Insulation with Phase Change Materials

Temperature
System Shut Down

Heat Released by
Phase Change
Material

Temperature
System Start-Up

Time
Heat Absorbed by
Phase Change Material

Time
 Transportation

Pipelines – Insulation on Operational Fields

Pipeline U Values (W/m2.K)
1.4

1.2

1
Dunbar TOTAL North Sea 170 16"/20"
U (W/m2.K)

0.8 ETAP Shell North Sea 90 12"/16"

Tchibeli TOTAL West Africal 200 10"/12"
0.6
Bonga Shell West Africal 1100 10"/12"

0.4
Forvie Shell North Sea 140 15"/17"
Rosa TOTAL West Africal 1470 9"/11"
0.2 USAN TOTAL West Africal 800 113/4"/14"

0
0 10 20 30 40 50 60 70

Pipe Length
 Transportation

Material Property Requirements for External Insulation

(OTC14116)

Primary Importance:
•Thermal conductivity
•Specific heat capacity
•Hydrostatic strength
•Ageing resistance (thermal, chemical,
oxidative)
•Water absorption (rate, total,
permeability)
 Transportation

Typical Cooldown Time Requirements

•4Hours No-Touch Time
•Incident analysis
•Equipment preparation
•Dead Oil Circulation Time
•Requirements (typical)
•Trees/Jumpers: 8 hours from 55 C to 20 C
•Flowlines: 16 hours from 51 C to 20 C
•Risers: 16 hours from 51 C to 20 C 70
Cooldown at Pipe Inlet

•Manifolds: limited by geometry. 60

2175

Compensated by MeOH injection 50

4350
6525
8700
Temp. (C) 40 10848
12943
14983
30 16970
18904
20783
20
20783
Wax Temp
Hydrate Temp
10

0
0.28
1.94
3.61
5.28
6.94
8.61
10.28
11.94
13.61
15.28
16.94
18.61
20.28
21.94
23.61
25.28
26.94
28.61
30.28
31.94
33.61
35.28
36.94
38.61
40.28
41.94
43.61
45.28
46.94
48.61
50.28
51.94
53.61
55.28
56.94
58.61
60.28
61.94
63.61
65.28
66.94
68.61
Time (Hrs)
 Cost Comparison for Subsea Elements
(Large Field)
9% Capex (100km)
5% 13%
2%

14%
Opex (10Yrs. 50km)

11%
7%
Deep Water 12%
600m 11%
30mbpd 57% 20%
100mmbbl - 15 yrs
7%Capex (150km)
GOR = 300 - 500 SCF/Stb 3%
10% 8%
1%
31%
18%
Slug Catcher(Top) Pipelines: Prodn., WI,Gas
Power Cable Umbilical (Chemical)
MPM MPP
Sep. Plant (Subsea)

61%
 Cost Comparison for Subsea Elements
(Small Field)

Capex (25km)
5% 10%
14%
4%

11% Opex (10Yrs. 50km)

11%
7%
12%
Shallow Water 10%
46% 11%
100m
10mbpd 20%
3% Capex (50km)
20mmbbl - 10 yrs 6%
GOR = 300 - 500 3% 8%
SCF/Stb 8%
14% 31%
Slug Catcher(Top) Pipelines: Prodn., WI,Gas
Power Cable Umbilical (Chemical)
MPM MPP
12% Sep. Plant (Subsea)
54%
 Design Considerations

• Understanding of the total system

• Reservoir, Well, Flowline, Host Processing
Facility, Water / Gas injection / lift and Chemical
Injection requirements.
• Characterisation of Reservoir Fluids
• Production Chemistry
• Multiphase Fluids Transportation
• Flowline Sizing
• Heat Balance and Insulation Requirements
• Corrosion / Erosion / other FA Issues
 Operational Considerations

• Operational Stability
• Slugging / Hydrodynamic / Terrain Induced
• Flow Rate Changes
• Low Temperatures
• Well Testing
• Shut Down / Re-Start / De-Pressurisation
• Hydrate, Wax, Scale, Erosion, Corrosion Control
and Management
100km Subsea Tie-Back Gas Field

• Gas Condensate + Saturated and Aquifer Water

• 500m of water depth
• Water Temp. of 5deg.C
•
• Processing Onshore.
• Reservoir Pressure of 400 bara.
• Reservoir Temperature of 100deg.C
•Seabed

••Reservoir
6 -8 Production wells.
•Wells

•Reservoir
•Reservoir
Production Profiles-Gas Field

Production / Depletion Profiles

500
450
400
350
300
250
200
150
100
50
0
1 3 5 7 9 11 13 15 17 19 21 23 25
mmscf /d
Ye ars
WHFP( Barg)
Water
 Operational Strategies

Issues:
• Hydrate avoidance
• Slug Control
• Low temperatures and compliance with material specs

Operations:
• Initial s/u and well / pipeline re-start up
• Low production operations
• Shutdowns either total or partial
• Pigging either intelligent or operational
Critical Operational Considerations

Failure of Hydrate Inhibitor supply:

• Detection Time of Event.
• Response Times to Corrective Measure.
• Development of Response Strategies.
Hydrate Plugs:
• Development of a Hydrate Plug Strategy.
• Detection ? Management ? And Controlled
Dissolution.
 The Total System- Reservoir
Considerations
• Reservoir recoverable reserves
• Anticipated production profile
• Pressure depletion characteristics
• Pressure maintenance requirements
• Temperature
• Depth to / of reservoir
• Production chemistry
• Optimise production, maximise recovery,
NPV and IRR.
Total System- Production Well

• No. of Wells
• TVD and profile
• PI Vs time
• Rock characteristics
• WHFP and WHFT
• Shut - in Pressure and Temperature
Total System- Flowline / Riser

• Optimise No. of flowlines /risers

• Internal Diameter
• Insulation requirements
• Burial and / or external insulation
• Terrain profile
• Riser type / profile
 Pipeline / Riser Sizing

• Minimise pressure drop

• Ensure stable operating conditions (low rates)
• Minimise slug sizes
• Achieve maximum throughput capacity
• Keep within the erosion limits
• Achieve required arrival temperature
• Avoid hydrate conditions
• Avoid Wax deposition conditions
• Enable well testing at low flow rates
• Production profile
• Flowline / Riser topography
Total System- Host Processing Facility
Considerations

• Existing or New Build

• Processing Limitations: Gas,
Oil, Water rates
• Slug handling capability
• Arrival temperature
requirements
• Flaring / blow down capability
Water
• Operating P & T specifications
Total System- Water Injection System

• Linked to reservoir simulation

• Pressure maintenance
• Replenish reservoir volume lost through
production
• Injection pressure
• Thermal fracture requirements
• Vacuum conditions
• Use of Aquifer water with gas lift.
Total System- Gas Injection / Lift

• Well bore gas lift

• Re-injection back into the reservoir
• Gas distribution system
• Gas lift control
• Inhibition against hydrates
• Low temperatures across annulus choke
Total System- Chemicals Injection

• Inhibitors (Corrosion, Scale, Hydrates,

Wax)
• Solvents (Scale, Wax)
• Biocides
• De-emulsifiers
• Anti Foaming Agents
 Flow Assurance – Software Tools

Resource
Description of Function Deliverables Designer
Title

Design and analysis of steady Pressures, velocities, liquid hold-up, Baker Jardine
PIPESIM
state multiphase systems slug characteristics and fluid properties Associates

Transient gas of liquid pipeline Energy

PIPELINE Pressure, velocities with distance and
network analysis programme Solutions
STUDIO time
(incorporates TLNET and TGNET) International

Pressure, velocities, liquid hold-up,

Transient multiphase pipeline
OLGA sweep-out, slug characteristics and Scandpower
analysis programme
fluid properties

Process unit simulator for refinery

modelling and limited pipe flow
HYSYS
analysis (separators, compression,
fractionation, columns, etc.)
Design and analysis of multiphase
NEOTEC
and single-phase pipelines
Thermal, mass and energy balance Hyprotech
analysis – can be modified for novel Simulation
applications modelling Engineering
Pressure and temperature profiles
Neotechnology
calculations, flow rate calculations,
Consultants
pipeline performance calculations etc.
 Summary of Development Issues

• Reduction of Drilling and Completion Costs with increased water

depth.
• Maximize productivity & reduce well numbers
• Large well-bores, Multi-laterals, Highly deviated and Smart wells
• Flow Assurance
• Slugging
• Low Pressure Reservoir
• Hydrates and pipeline blockage
• New technology required e.g. SS, MP & DHP’s
• Electrical power at the well head an issue
• Intervention Costs in remote locations
• Dry trees and Spars being considered in Deepwater developments
• Shortage of Resources
• Human
• Old Vessels
 Work Shop

Selection of Fields:
• Deepwater Oil field tie - back to an FPSO
• Long distance Oil field tie - back to
Platform
• Long distance Gas condensate to shore
 Work Shop

Typical F/A Design Process

•Obtain fluid samples and analysis
•Assembly of data (reservoir & fluids) and validations
•Fluids modeling: phase behavior & physical properties
•Solids potential and preliminary management strategy:
hydrates, waxes, asphaltenes, sands
•Steady state analysis for thermal and hydraulic requirements
•Analysis of system cool down
•Determination of insulation requirements
•Transient analysis for start-up, rate change, blow down, and
shut down
•Develop system design and operating procedures
 Work Shop

Design Basis
•Large body of information
•Vary in quality: complete/accurate, incomplete
•Examples of information needed
•Operating philosophy
•Field development philosophy
•Equipment design philosophy
•Region and environmental information
•Well counts and locations: producers, injectors
•Environmental conditions – ambient conditions
•Reservoir description
•Reservoir properties
•Production rates
•Fluid properties