SAND MANAGEMENT

CENTRAL AZERI CASE STUDY

HEMRAJ GAIDHANI, PhD

SAND MANAGEMENT
Agenda
Introduction Flow Scheme & Design Basis Overview of Test Runs Results of Test Runs Solutions to be reviewed
- Sand Removal from Separators - Sand Separation Package Performance - Sand Jetting Pump - Changes to Sand Separation Package Flow Scheme - Sand Jetting Control

Combination of TORE Desanders with Conventional sand Jetting

- Feasibility Study proposal - Previous Investigations by BP/KBR

Questions
2

INTRODUCTION

The primary objectives of the Sand Management Study for CA, was to: - Identify the root causes of the Sand Jetting pump failure. - Propose short, medium and long term solutions that will enable the sand removal / separation systems to function per design intent. - Identify potential modifications to minimise Operations involvement in the sand jetting process.

INTRODUCTIONS
Why is Sand Removal Important?
Reduces separation efficiency due to the reduced volume available for fluid separation

Microbial Induced Corrosion (MIC) of Separator cladding may occur

Potential to erode the downstream LCV, Pipes, etc

Sand production is expected to increase with increased water cut

Flow Scheme of CA Sand Separation Package

Topsides Package

SEPARATORS

Gas

SURGE VESSEL
Vent

Jetting Header
PDC 580144 PC 580154

Oil

Oil

LC 580151

Slurry Return
XXV 580145

Sand Cyclones

Water

TORESCRUB HYDROCYCLONE
Sand Jetting Water Supply
XXV 580152 FC 580151

Makeup (intermittent)

Excess Water Dump (not in use)

MAIN JETTING PUMP SAND BAGGING OR CUTTING REINJECTION TANK

DESIGN INTENT
Sand Separation Package Performance Specifications:

10% of particles from the separators are less than 30 microns.

(based on produced sand with 75% less than 200 microns, D50 = 130 microns)

Jetting water circulation flow rate of 81m3/h. Designed for a maximum slurry concentration of 50 wt% (i.e. 27 vol%.) in the outlet stream from the separators Designed for maximum 1000 ppmv free oil in water to the hydrocyclone

Remove 95% of sand particles greater than 30 microns in the sand slurry to the Torescrub
6

FACTS AND EXPECTATIONS

RESULTS OF TEST RUNS

May 2005 (Trial-1):

Train 2 HP separator was sand jetted online. The jetting pump 1D-P58011 discharge pressure dropped from 69 barg to 60 barg in 6 minutes. This suggested sand erosion of the Pitot Tube in the pump and was thought to be due to sand carryover to jetting pump without effective removal in the Torescrub 1D-V58014.

RESULTS OF TEST RUNS

Oct 2005 (Trial -2):

Installed an up-stand pipe inside the surge vessel 1D-V58015 to attempt to limit sand carryover to the jetting pump. To reduce sand concentration in the slurry entering the Torescrub diluted the slurry by partially bypassing jetting water around the HP Separator.

RESULTS OF TEST RUNS

Oct 2005: LP Separator Sand Jetting

A very small quantity of sand was recovered

The concentration of sand to sand jetting pump was 0.06 wt%, less than the pump design tolerance of 0.1 wt%.

Sample Downstream of Main Pump

10

RESULTS OF TEST RUNS

Oct 2005: HP Separator Sand Jetting

- 600 litres of sand was collected from the Torescrub in 10 minutes - Oil carryover with sand (like Porridge) - 70% of the solids particles are larger than 200 micron in size

Sample from Sand Bagging

11

RESULTS OF TEST RUNS

Oct 2005: HP Separator Sand Jetting

- 70% of the solid particles are larger than 30 micron in size - Torescrub Design Criteria: 95% removal efficiency for particles 30 microns or larger. - Oil carryover with sand

Sample from Surge Drum

12

TEST RUN CONCLUSIONS

Expected Produced Sand:

-75% of the solids particles smaller than 200 micron in size - Avg. particle size (D50) 130 microns
GCA#1: Average of 5 Samples Cumulative % Greater Than vs Size
110% 100% 90% 80% 70%

Cumulative %

60% Series1 50% 40% 30% 20% 10% 0%

Design Criteria

10

100

1000 M. Bothamley June/99

Particle Size, microns

13

TEST RUN CONCLUSIONS

Actual Produced Sand: -75% of the solids particles are larger than 200 microns - Average particle size (D50) is 240 microns

Q - Does it affect performance of Torescrub, effective fluidisation in Separator?

14

RESULTS OF TEST RUN

Oil Loading :

Sand jetting Nozzles Oil/Water Interface

Wax Formation (based on Nov 2006 Thermographs) :

Temperature of the sand layer is approximately 42C which is the wax formation temperature of the production fluids. Low temperature promotes wax formation in any oil retained in the sand layer.
Slurry Concentration :

No Control available

15

RESULTS OF TEST RUN

Main Jetting Pump: Rotojet/Pitot Tube Type Pump Sand separation package is designed to handle 50 wt% sand slurry
(and 23% on EA/WA).

10% of total particles were expected to be less than 30 microns (i.e. 5 wt%).
Torescrub is designed to remove 95% of particles greater than 30 microns. i.e. 5% particles greater than 30 microns carry through to downstream equipment

Carry over Sand from Torescrub = 5%+ 2.25% = 7.25 wt%.

These solid particles accumulate in the Surge Vessel up to the stand pipe and would be carried through to the jetting pump suction.

The design solid loading for the main jetting pump is only 0.1 wt%

16

Solutions to be reviewed

1. Sand Removal from Separators 2. Sand Separation Package Performance Sand Loading Oil Loading/Wax Formation 3. Main Sand Jetting Pump 4. Sand Jetting Control and Changes to Sand Separation Package Flow Scheme

17

Solutions to be reviewed
1. Sand Removal from Separators

Replacement of Jetting nozzles with Tore or Combination of Existing Jetting with Tore system
1. Start of jetting
Original sand layer

Suction point Nozzle Nozzle fluidisation flow

2. End of jetting

Nozzle

Fluidised sand particles

Tore system Jetting nozzles

18 18

Solutions to be reviewed
2. Sand Separation Package Performance

Sand Loading
Short Term :

Limit Sand build up Dilute the Slurry flow Surge vessel stand pipe modification Change in Torescrub Internals/Cyclones

Medium Term : Long Term :

Change in jetting internals of separators Increase in circulation rate Dilute the Slurry flow (high capacity pump) Torescrub Replacement

19 19

Solutions to be reviewed
2. Sand Separation Package Performance

Oil Loading/Wax Formation

Short Term Solutions:

Maintain water level in separators Chemical Injection

Medium Term Solutions:

Hot water circulation (WA Trials)

Long Term Solutions:

Increase Separator Sand Weir Height

20 20

Solutions to be reviewed
3. Main Sand Jetting Pump Modifications

Short Term :

Internals Modification
Medium Term :

Add Pump Suction Strainer

Long Term :

Replace Pump Additional Sand Filtration

21 21

Combination of Tore Desanders with Conventional Sand Jetting

- Feasibility Study proposal - Previous Investigations by BP/KBR

1. Start of jetting

Original sand layer

Suction point Nozzle Nozzle fluidisation flow

2. End of jetting

Nozzle

Fluidised sand particles

Tore system Jetting nozzles

22 22

Combination of Tore Desanders with Conventional Sand Jetting

Feasibility Study proposal
Compatibility check of TORE with Sand Skid Operating Philosophy Process Control around Separator to maintain Sand Slurry Concentration Vendor Evaluation Increase in Weir height in HP separator

Previous Investigations by BP/KBR

23 23

Thank You & We Welcome Your Comments and Questions

24