SPE

SPE 14687 Hydrocarbon Miscible Flood: Field Facility Design

by K. Verma and P. Giesbrecht, Amoco Canada Petroleum Co.

Copyright 198S, Society of Petroleum Engineers This paper wee presented at the SPE 198S ProductionTechnologySymposiumheld in Lubbock,Texaa November 11-12, 19SS. The material is subject to correctionby the author. Permissionto copy is restrictedto en abstractof not more than 300 words. Write SPE, P.O. Sox 832S36, Richardson,Texas 750.93-363S. Tafax 7309S9 SPE DAL.

ABSTRACT

INTRODUCTION

This paper summarizes the design, selection, ~nstallation and operational aspects of hydrocarbon miscible flood field facilities. Field facilities discussed include solvent and gas, fresh and produced water injection pipelines, double block and bleed system, and injection wellhead. The piping design for high pressure injection system is described to explain the economics of selection of high grade pipe.

With the increase in the number of enhanced recovery projects, it is helpful for all operators to have benefit of the experience obtained to date in order that future projects may proteed as smoothly as possible. The design, installation and operational techniques mainly focus on South Swan Hills Unit (SSHU) and Nipisi Gilwood Unit No. 1 (NGU) hydrocarbon miscible flood field facilities. The South Swan Hills Unit as shown in Figure 1 is located approximately 225 km (140 mi) northwest of Edmonton. There are currently 188 producing wells, 16 produced water injectors and 48 miscible injectors. During 1984 the average daily oil production was 3 620 m~ (22 770 BBL). Nipisi Gilwood Unit No. 1 is approximately 273 km (170 mi) northwest of Edmonton (Figure 1). There are 120 producing wells, 32 produced water injectors and 6 solvent injectors. The average daily oil production for 1984 was 6 000m3 (37740 BBL).

In a cyclic miscible injection system, hydrate formation is the main operational problem. This paper presents the rationale for selection of the unique design of double block and bleed system. The simplicity of this design has reduced operating costs. The techniques involved in switching the cycles from solvent injection to water and vice versa are described.
Field facilities pressure testing has always been an outstanding question, especially for miscible injection lines. Water, gas and methanol as test media are evaluated.

HYDROCARBON MISCIBLE FLOOD - FIELD FACILITY DESIGN The major design areas of a miscible flood field facilities are: 1. 2. 3. 4. 5. Injection system, Solvent and water injection lines, Double block and bleed system, Pressure testing procedures, Switchover procedure from solvent to water injection and vice versa.

SPE 14687

be provided to accommodate future requirements and to have operating flexibility. Once the injection volumes and design pressure parameters have been determined, the detailed facility design can proceed. $ INJECTION PIPELINE DESIGN

Other field systems such as fluid gathering, automation and injection well downhole equipment are equally important, but are not addressed in this paper.

Solvent and water injection lines should be designed to obtain optimum pipe diameters and pressure drops, keeping in mind the future variation in injection rates and tie-in of additional wells. The optimum pipe size is dependent on pipe cost versus pressure drop cost. For preliminary studies, one may take a short cut by assuming a line velocity of 2-3 m/s (6-10 ft/see) to establish diameters for water injection lines. With these diameters and estimated lengths, a tentative grid may be drawn. The pressure drop for each leg is calculated and one can work through the grid to find the pressure distribution. Based on pipe and installation costs, the trunk line grid systems are usually more economical than radial grid systems. Once the pipeline grid has been established, the pressure drop in water injection lines should be rechecked by using the Hazen-Williams formula: PI - P~ Q(m3/h) = 3.76 x 106 x d263 x C x [L]

INJECTION SYSTEM

The injection system is designed to distribute solvent (denk.egas phase), produced and fresh water from plant sites to injection wells. The solvent stream consists of natural gas plus ethane rich natural gas liquids in a certain ratio to ensure miscibility at reservoir conditions. Enriched gas solvent and water are injected alternately to increase the recovery of oil. The solvent injection system is completely separate from the water injection system.

054

Due to the difference in densities between so vent and water, a higher surface pressure is required for solvent injection to obtain the same bottom hole pressure. The required Surfi ce injection pressure is calculated by determining the wellbore bottom hole pressure and using BWRS equation of state to calculate the solvent density. For water, the injection pressure is the bottom hole pressure minus the hydrostatic head of tubing water column. The wellhead~njection pressure is adjusted for tubing trlctlon and wellhead pressure drop. ga~e~ on these values, plant discharge pressures are determined by adding pipeline network pressure drop and adjusting for pipe elevation changes, etc. For example, the design pressure for SSHU and NGU injection facility is 39 990 kPa ~~lv~nt and 24 130 kPa {n nnn \w n.i) !-., for (3 500 psi) for water. Miscible injection project extensively involves reservoir computer models to simulate the reservoirs characteristics and match against its past performance. These models are then used to predict the production and injection rates for each well. These rates are the basis of all designs for field facilities. The final decision to establish the solvent and water plant discharge pressures and plant capacities is based on various other factors. Some of those factors are Voidage Replacement Ratio, change in reservoir pressure, tie-in of additional wells, government and regulatory agency requirements, etc. A sufficient margin should

The internal pipe diameter (d) should be corrected for internally cement lined or coated pipe. The value of Constant (C) is 120 for cement lined pipe where scale or other accumulation is anticipated, and 140 for clean and nonscaling service. Solvent injection lines may be designed as a single phase flow system. Normally, injection pressure is much higher than critical pressure. Figure 2 shows the phase envelope for NGU miscible flood stream. The critical pressure on the phase envelope is only 11 000 k% (1 595 psi) whereas actual injection pressure is over 27 500 kPa (4 000 psi). At this high pressure, the solvent stream is in dense gas phase. -.--To calculate the pipe diameters and pressure drop for solvent injection lines, the use of a particular equation is usually a matter of convenience or company tradition. Most equations can be used satisfactorily if attention is given to the proper use of efficiencies and friction transmission factors. Any good evaluation should include the results obtained from more than one equation. The Darcys flow equation with Moodys friction factor correction is commonly used for single phase flow. One form of this equation can be shown as: AP(kPa) =62.6x104xfLW2V

SPE 14687

KASH.YERMA

PETER GIESBRECHT a.

Once pipe diameters have been established, the pipe wall thickness should be determined according to ANSI Specifications 831.8 Gas Transmission and Distribution Piping System. tr= POD m + t-

Ensure end joints are square and the cement lining is in good condition. Minor damages in cement lining can be repaired with a special compound as per manufacturer recommendations. , Preheat both ends as per welding specifications. Apply glue to one side of the gasket and install the gasket on one pipe end. Align the gasket properly to the cement lining. From past experience, it was found that Inconel k-1000 gaskets perform best. Gasket dimensions should match the dimensions of the cement lining. Move the ends of the pipes together leaving a predetermined gap between the gasket and the cement lining. This gap is provided for pipe shrinkage due to welding. Figure 3 shows amount of shrinkage per weld on 114.3 mm0.D. (4.0 in), 11.13 mmwall (O.438 in) wal 1 thickness, GR-359 (GR-52) pipe. If the proper gap is not provided, the cement lining may crack during welding and expose the pipe. The shrinkage allowance for each size and grade of pipe should be established for welding cement lined pipe. Apply a stringer bead, leaving a vent hole in the stringer bead to vent out steam from welding heat on the cement lining. Grind the vent hole. The vent hole can be filled in during next hot welding pass. Complete the weld joint as soon as possible to maintain the heat in the steel and the cement lining. Wrap the weld to ensure slow cooling. The injection lines are x-rayed to meet the weld quality specifications. The line should be holiday inspected and properly backfilled with no rocks located near the pipe to damage it.

il.

A careful consideration should be given to material grade selection. A cost comparison shows that investmentcost can be lowered by the use of X-grade pipe over A106 or A53 grade B pipe. The common type of X-grade pipe is GR-35, GR-42, GR-46, GR-52 and GR-65. Based on past experience, material cost, problems in welding and availability of pipe, flanges and fittings etc. , GR-52 is preferred. The pipe wall thickness was selected to provide 1.59 mm (0.062 in) corrosion allowance. Corrosion allowance greater than 1.59 mm (0.062 in) may be incorporated where extreme corrosion conditions exist and corrosion inhibitors are impractical or uneconomical. The use of seamless or electric resistance welded (E.R.W.) pipe should be evaluated. Seamless pipe is approximately 10% to 15%more expensive than E.R.W. pipe. To minimize the installation cost, the injection pipe should be at least double random length with ends bevelled for welding. Injection lines should have external protective coating. The produced water lines should be protected internally. The coating for the joints and fittings should be compatible with the rest of the line. If corrosion inhibitor is used for internal protection, the corrosion coupons should be placed at various locations to monitor the program. Cathodic insulation kits are required wherever the level of cathodic protection changes, eg., wellhead. Amocos SSHU and NGU solvent and water injection lines are coated externally with extruded polyethylene. Produced water injection lines are coated internally with cement lining. Dependability and safety of equipment is contingent on the proper seiection and installation of pipe, valves and fittings, etc. Extra precaution is required for injection facilities due to high pressure rating. The flanges, fittings and valves must have at least the same pressure rating as the pipeline. All flanges at high injection pressure are RTJ type with stainless steel oval ring. The stud bolts and hexagonal nuts should be selected as per ASTM specifications A193 and A194. Valve bodies in the injection system are of carbon steel structure, with internais to match the antic~rr~sien requirements. Construction procedures for welding the injection lines should be as per API Specification 1104. The welding of cement lined pipe requires special precautions. Some of the important points are summa-rized below:

c.

d.

e.

f.

9.

The location and design of isolation stations <mnnm+an+ nat+ ~f ~n~ pinina network. .-.... alc all ,,up. .. y. Preferably, each subsection of~ip;ng should be isolated from the main injection leg. The isolation stations provide operational flexibility, and are required to repair and test the piping sub-sections without shutting down the entire injection system. Each isolation station should have a bleed-off valve, a fitting for pressure gauge, and a sampling point on each side of the block valve and prwision for a spectacle blind during pressure test~ng. . A typical design of an isolation -- :..:--<a = =+iS shown in lllJSVtlun aj=station iii d]] Figure 4. Piles should be driven on each side to carry the total weight. If the pipeline fluid is of such temperature to cause any distortion due to pipe expansion, a tie bar between the ends as shown should be installed to

HYDROCARBON MISCIBLE FLOOD - FIELD FACILITY DESIGN transmit the pipe expansion to the next expansion iOOp.

SPE 14687

solvent injection ESD valve. As shown in Figure 6, the well easing has a relief valve Gpefito atmosphere to release high casing pressures.
Tha
lllG

~~+c,wiwI
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b,my

ad
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t.mllbaa,-i farilitioc
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The double block and bleed system is a wellsite installation developed by Amoco Canada Petroleum Company Ltd. The system is designed to inject solvent or gas and water alternatively into the wellbore without hydrate formation. The design has been modified over years of operational experience. Figure 5 shows the arrangement of the double block and bleed system. The installation is grouped into two sections: the metering facility and the wellhead facility. The metering facility is minimum 46 m (150 ft) from the wellhead facility for safety reasons and to facilitate service rig access. The metering facility is a fixed installation whereas the wellhead facility is a removable installation and is dismantled during workover operations. Originally Amocos SSHU facilities had a common line for solvent and water injection from the metering station to the wellhead. The injection fluids were measured by a common meter run and controlled by a choke. Subsequently, it was sv~tems for Solvent m~dif~~d to ~~n two ~~narat.p ~-. ---J & -----and water to avoid frequent expensive hydrate ~orma~ion problems.

nclosed in insulated and heated buildings. lhe wellhead building has lifting hooks for removal during workover operations. The solvent and water injection lines are color coded for proper identification.

PRESSURE TESTING PROCEDURES

The injection lines should be tested to at least 1.25 times the design operating pressures, but the test pressure shall not result in circumferential stress in excess of 90% of the specified minimum yield stress of the pipe material. The preferred test media for solvent injection lines is methanol. Natural gas, air, nitogen, etc:, can be used, but due to the compressibility factors of these gases, it is difficult to obtain conclusive results. Water should not be used in solvent lines testing because hydrate formation will be a major problem during the start-up period of solvent injection. The logical test media for water injection lines is fresh water. Methanol is better than gas or air for safety :A---*:--- ...A:& . .. . k..A.,..A +r.. nwefowwn,-l
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The metering facility has two separate injection lines, one for the solvent, and the other for the produced or fresh water. Each line has a block valve to isolate the lease from the main injection line, an orifice type meter run to measure the injection volumes and a choke to restrict the injection rate. Downstream of each meter run, there is a 25 mm (1 in) needle valve to inject methanol during cycle switchovers. The solvent line has a 60mm (2 in) bleed-off valve to atmosphere to release the line pressure. From the metering facility, the water and solvent lines run underground to the wellhead facility. This prevents freeze up of water injection lines and to ensure a clear access around the wellbore for equipment when required. The wellhead facility is shown on Figure 6. The API 34 500 kPa (5 000 psi) wellhead has two injection arms 180 apart: one for the solvent and the second for water injection. These arms can be disconnected between the check valve and the breakout flange to accommodate the workover rig. After fabrication the produced water arm is internally coated for corrosion protection. ~~ ~~~~~~~~~g ~~~ ~~ ~~~~~]~~~ ~p~~p~s~ of ~~~ check valve for cathodic protection. The emergency shut down (ESD) valve on the solvent injection side is connected to a well casing pressure sensor. If there is any communication between the tubing and the casing, the casing pressure sensor automatically closes the

color to assist in locating the leaks in the installation. Depending on the variation in elevation of the pipeline, most of the methanol can be recovered by injecting natural gas after the test cycle, and reused in day-to-day operations, resulting in no waste or disposal problem. The following test procedure may be used for pressure testing injection lines: a. Install all necessary blinds, block valves, sample valves, instrument valves, bleed-off valves and plugs, etc. Install pressure gauges and recorder. Start filling pipeline from the lowest point and bleed off air from high point at each section. When all the air is bled out, increase the pressure to about 1/3 of test pressure and check for leaks. Maintain this pressure for about 4 hours, then increase the pressure to 2/3 of the test pressure. Maintain this pressure for about 4 hours and check for leaks. Then brina the pressure UD to test pressure plus 400 ~Pa toaccommodate any variation due to temperature changes, etc.

b. c.

d.

e.

f.

PE 14687 9. h.

~Sti YEHMA After the pressure has stabilized for one hour, start chart recorder. Check the chart recorder every two hours for the first eight hours, unless the lines are close to a residential area or a main highway. Run pressure test for full 24 hours.

PETER GIESRRECHT No problems exist with the pressure difference in switching from water injection to solvent injection. However, in some instances, the solvent pressure drop through the wellhead can be large and can cause a hydrate formation due to temperature reduction. To avoid this problem, s it is recommended to inject 1 m3 to 2 m3 of methanol down the water injection leg before switching over to solvent injection. The design of hydrocarbon miscible flood surface facilities is a relatively straightforward technique compared to more complex installations. Nevertheless, the design, selection, installation and operation of the system from plant site to the wellbore does demonstrate the total concept of handling solvent and water at high injection pressures.

i.

After the pressure test, slowly drain the system. Chase gas may be injected in solvent injection lines to recover methanol.

PROCEDURE FOR CYCLE SWITCHOVER

A defined procedure should be adopted when switching from solvent to water injection, and vice versa, to avoid hydrate formation. The frequency of switchover can vary from project to project. All switchovers are scheduled to be performed manually, unless the switchover frequency is high enough and automation can be economically justified. Each type of switchover presents different problems. In switching from solvent to water injection, the biggest difficulty is the pressure difference between the solvent and water injection system. In order to overcome this pressure difference, a high pressure pumping unit to inject methanol into the system is recommended. The following procedure may be used in the switching from solvent to water injection:

CONCLUSIONS

The overall operating success of any surface facility of this type is not only tied to the engineering design, but also on the installation and operating techniques. It is only through the actual operational experience that the optimum design can be determined. The facility design presented in this paper was developed over years of practical experience. The solvent and water injection system offers operational flexibility, safety and reduced operating costs. As a final comment, the hydrocarbon miscible flood design, like all other designs, has its limitations and is subject to development and change. Nevertheless, the experience accumulated to date should benefit all operators to ensure the success of enhanced recovery projects.

a. b.

Shut the main block valve for the solvent injection line in the meter run facility. Connect the pump discharge line to the solvent injection line at the 25 mm (1 in) needle valve downstream of meter run. Inject 1 m3 to 2 m3 of methanol into the systern. Close the solvent and open the water wellhead valve. Slowly open the water injection block valve and start injecting water. If it appears that water is not going into wellbore, the main block valve should be closed. Connect the pump discharge line to water injection system, and displace the well tubing fluid with water. When the tubing pressure drops, the water injection block valve can be opened and the well should begin injecting.

c.

ACKNOWLEDGEMENTS

d.

e.

The authors wish to acknowledge the many people at Amoco Canada Petroleum Company Ltd. whose efforts resulted in this paper. We express our thanks to R. G. Passmore, R. H. Czemeres, R. J. Dreveny and B. P. Uhrich for their guidance and encouragement. We also w~sh to thank Amoco Production Company for their permission to present this paper.

f.

SPE 14687 6 REFERENCES HYDROCARBON MISCIBLE FLOOD - FIELD FACILITY DESIGN I

1.
2.

Amoco Production Company, Engineering Specifications, Volumes 111 and IV. Alderman, O. H., McFarland, R. M., rncint.yre, J. w., biin~ssale,~. ~:, Roye, J. E.,Jr.; Field Facllitles for COZ Tertiary Floods - A Conceptual Oesign SPE-AIME Paper 11234 presented at the 57th Annual Fall Technical Conference and Exhibition held in New Orleans, LA, September 26--29, 1982. Hamaker, R. J.; Surface Faciliti~s for -. Inert Gas Generation and Compression tasz Binger Unit, Caddo County, Oklahoma SPEAIME Paper 7798 presented at the 1979 Production Operations Symposium held in Oklahoma City, OK, February 25-27, 1979.

3.

APPENOIX

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diameter

of

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millimeters

c
PI P2 L AP f

Constant; accounting for pipe roughness

= Initial pressure; kilopascals (kPa) = Final pressure; kilopascals (kPa) = Length of pipe; meters = Pressure drop; kilopascals (kPa) = Moodys friction factor Rate of flow; kilogram per hour

w= u tr tc
P. D

= = =

Specific volume of fluid; cubic meters pe hour Required pipe wall thickness; millimeters Corrosion allowance; millimeters

= Design pressure; megapascals (mPa) = Outside diameter of pipe; millimeters

s ~=
F T

Specified minimum yield strength megapascals (mPa)

Innnitudinal --..=--------ioint *. .. . type derating factor design factor factor

= =

Construction Temperature

WE

14681?

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MILES

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FIGURE 1

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3000 I

200

1000

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Deg. C Injection Pressure: 27,500 (4,000 PSI) I niecti.m Temperature: 23 C (73F)

PHASEDIAGRAM NIPISI HYDROCARBON MISCIBLE INJECTION STREAM FIGURE 2

Measurement Before Welding Measurement After Welding K 40.640 cm 40.474 cm ~

BEFORE WELDING

AFTER WELDING

SHRINK TESTON 114.3mm OD 11.13mm WT GR359 PIPE FIGURE 3

.PL
Ground Lavel

Line Injection

1.Driven
2. 3. 4. 5. 6. 7. 8.

piles for pipe support

H. Beam 0.5 m Long one size larger pipe split in half 12 mm pressure gauge and sample valve 25 mm drain valve SPec. Blind to withstand design teat pressure Main block valve Ti*bar (if raquired) same size as inimtion line to trantmit pipe expansion

FIELD ISOLATION STATION FIGURE 4

Wellhead I

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00UBLE BLOCK ANO BLEEO SYSTEM FIGURE5

/
Water Line Solvent Line

SPE

14687

F Iare

to Atmosphere

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- Breakout m F lan9e

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Solvent

Water

MISCIBLE

INJECTION FIGURE 6

WELLHEAD