EG55F8 Flow Assurance

MSc in Subsea Engineering

Introduction and Key Concepts in Flow Assurance Introduction and Key Concepts in Flow Assurance Introduction and Key Concepts in Flow Assurance Introduction and Key Concepts in Flow Assurance
Murray Anderson Murray Anderson BEng BEng PhD PhD CEng CEng MIMechE MIMechE
Head of Flow Assurance and Field Development Engineering, Atkins Head of Flow Assurance and Field Development Engineering, Atkins
Murray Anderson Murray Anderson BEng BEng PhD PhD CEng CEng MIMechE MIMechE
Head of Flow Assurance and Field Development Engineering, Atkins Head of Flow Assurance and Field Development Engineering, Atkins
EG55F8 Flow Assurance
MSc in Subsea Engineering
Subsea Pipeline Flow Assurance
Introduction to Flow Assurance
The main flow assurance challenges
Production fluids and phase behaviour
Multiphase flow
Hydrates, wax and asphaltenes
Overall Heat Transfer Coefficient
Insulation systems (wet insulation and pipe-in-pipe)
Heating systems
Chemical treatments
Operating strategies
Conclusions and key messages
EG55F8 Flow Assurance
MSc in Subsea Engineering
Oil and Gas Development Options
Onshore Shallow-water Offshore Deep-water Offshore
Shallow Reservoir
Deep
Reservoir
Subsea Step-out
Deep-water
HPHT
Deep-water
Cluster
up to
3km
up to
10km
Deviated
Well
up to
150km
up to
5km
Impermeable
Cap Rock
Oil/Gas bearing Rock
Fault Fault
EG55F8 Flow Assurance
MSc in Subsea Engineering
Reservoir Pressure
4
EG55F8 Flow Assurance
MSc in Subsea Engineering
Flow Assurance Definition
Themo-hydraulic
Modelling
System
Design
Processing
Requirements
Appraisal
Pressure
Profiles
Design
Concept
Sampling
Operating
Philosophy
Temperature
Profiles
Pipeline Sizes
and Pressure
Protection
Fluid Analysis
Start-up and
shut-down
Flow Regimes
Insulation and
Thermal
Management
Fluid Modelling
Pigging and
Planned
Intervention
Hydrates, Wax,
Asphaltenes
and Scale
Chemical
Requirements
Un-planned
intervention
System
Operation
Project Life Cycle
EG55F8 Flow Assurance
MSc in Subsea Engineering
The Main Challenges
Flow Instabilities:
Multiphase flow
Slugging
Pipeline Blockages:
Hydrates
Wax
Asphaltenes
Scale
Loss of Containment:
Corrosion
Erosion
Much of the flow assurance challenge
reduces to identifying, understanding
and managing uncertainty
EG55F8 Flow Assurance
MSc in Subsea Engineering
Deep Water Challenges
Remote and inaccessible.
Low ambient water temperatures.
Long distance tie-backs.
Long risers.
Extremely high cost of intervention.
Complex subsea systems.
BP operated Nakika floating production facility in
1930m water depth in the Gulf of Mexico
FPSO Espirito Santo moored in 1789m in the
Campos Basin off Brazil
Minimise hardware CAPEX while assuring OPERABILITY
EG55F8 Flow Assurance
MSc in Subsea Engineering
Hydrocarbons Fluids
Hydrocarbons
Aliphatics
Aromatics
Alkanes
(Paraffins)
Alkenes
(Olefins)
Alkynes Cycloaliphatics
C H H
H
H
C H
H
H
C
H
C
H
H
H
C H H
H
methane
ethane
propane
n-butane
iso-butane
(methylpropane)
C H
H
H
C
H
H
H
C H
H
ethene
(ethylene)
propene
(propylene)
ethyne
(acetylene)
propyne
C
H H
C H
H
cyclopropane
C H
C
H
C
H
C
H
C
H
C H benzene
C
H
H
C
H
H
C
H
H
C
H
C
H
H
H
C C H H
C H C C
H
H
H C H
H
H
C
H
H
C
H
H
H
C H
H
H
C
H
H
C
H
H
C H
H
H
EG55F8 Flow Assurance
MSc in Subsea Engineering
C
Non- hydrocarbon Fluids
S
H
H C
H
H
O C O
H
H
C
H
H H
H
O H
H
H
H
Non-hydrocarbons incorporate atoms such as nitrogen, oxygen and sulphur
Organic Compounds
Resins and
Asphaltenes
Alcohols Glycols
Mercaptans
(Thiols)
Inorganic Compounds
methanol
ethanol
(IMS)
MEG
methyl mercaptan
O C
H
H
H
H C
H
H
N N nitrogen
H O
H
water
O C O
carbon
dioxide
H S
H
hydrogen
sulphide
solids
metals
ASPHALTENES are insoluble
in petroleum and are solid and
nonvolatile
RESINS are readily soluble in
petroleum and may be volatile
liquidsor sticky solids
Hg, Ni, V
large organic molecules with
ring structures and one to
three sulphur, oxygen or
nitrogenatoms
mineral salts
sand,
diamondoids
CaCO
3
, BaSO
4
,
NaCl
Non-hydrocarbons
EG55F8 Flow Assurance
MSc in Subsea Engineering
Single-component Phase Behaviour
Critical Point
Triple Point
Liquid
Gas
Solid
Dense Phase
Supercritical
Superheated
Gas
Temperature
P
r
e
s
s
u
r
e
EG55F8 Flow Assurance
MSc in Subsea Engineering
0
20
40
60
80
100
120
140
-100 -80 -60 -40 -20 0 20 40 60
P
r
e
s
s
u
r
e
(
b
a
r
a
)
Temperature(C)
Multi-component Phase Behaviour
Cricondenbar
C
r
i
c
o
n
d
e
n
t
h
e
r
m
Critical Point
Liquid
Multiphase
Gas
10%
20%
30%
70%
50%
40%
Dense Phase
Typical Rich Gas, S.G. ~1.0
EG55F8 Flow Assurance
MSc in Subsea Engineering
Multiphase Flow Regimes
Stratified/Wavy Flow:
Liquid and gas separate due to low gas velocity
Velocity differences may produce surface waves
Often seen in downward sloping pipe sections
Dispersed Bubble Flow:
Liquid dominated systems with low gas rates
Occurs at all angles of inclination
Appears as gas bubbles entrained in liquid phase
Annular-mist Flow:
Gas dominated systems with low liquid rates
Occurs at all angles of inclination
Appears as liquid droplets entrained in gas phase
Hydrodynamic Slug Flow:
Surface waves in stratified flow bridge the pipe
Flow can be very unsteady
Often seen in upward sloping pipe sections
EG55F8 Flow Assurance
MSc in Subsea Engineering
Multiphase Flow Parameters
g
A
l
A
Superficial
Velocity
Phase volume flow
Total cross sectional area
g l
l
l s
A A
Q
V
+
=
g l
g
g s
A A
Q
V
+
=
Mixture
Velocity
Total volume flow
Total cross sectional area
g s l s
g l
g l
m
V V
A A
Q Q
V + =
+
+
=
Phase
Velocity
Phase volume flow
Phase cross sectional area
l
l
l
A
Q
V =
g
g
g
A
Q
V =
Liquid
Hold-up g l
l
l
A A
A
H
+
=
Phase cross sectional area
Total cross sectional area
Dispersed Bubble
Stratified/Wavy
Hydrodynamic Slug
Annular-mist
log(Superficial Gas Velocity)
l
o
g
(
S
u
p
e
r
f
i
c
i
a
l
L
i
q
u
i
d
V
e
l
o
c
i
t
y
)
g
V
l
V
EG55F8 Flow Assurance
MSc in Subsea Engineering
Gas
Why is it important?
Pipeline Sizing
Small diameter gives increased pressure loss but reduced slugging
Liquid Loading:
High pressure required to restart wells
Equipment sizing for initial start-up slug
Large liquid volumes during pigging
Steady-state Transients:
Vessel sizing must accommodate maximum slug
High loading/fatigue on pipe supports
Downstream process stability (gas starvation)
Production Flowline
Gas Lift Flowline
Riser Base
Gas Lift
Manifold
Well-head
Well-head
Water
Oil
EG55F8 Flow Assurance
MSc in Subsea Engineering
Hydrates
Hydrates are crystalline solids formed in the
presence of water and small non-polar molecules
Hydrates are ice-like compounds
Hydrates form at high pressure and low
temperature
Critically, at high pressure hydrates can form at
up to 30C
0.1m
3
hydrate ~ 18scm gas!
EG55F8 Flow Assurance
MSc in Subsea Engineering
1
10
100
1000
0 5 10 15 20 25 30 35
P
r
e
s
s
u
r
e
(
b
a
r
a
)
Temperature (C)
Methane Ethane Carbon Dioxide Hydrogen Sulphide
Hydrate Formation
Hydrates form when a small molecule
(guest molecule) stabilizes hydrogen
bonds between water molecules (host
molecules)
The host molecules form cages (12,
14 or 16 sided) round the guest
molecule
Different hydrate types have different
cage configurations
Type I hydrate: 2 x 12 sided cages + 6 x 14 sided cages
Type II hydrate: 16 x 12 sided cages + 8 x 16 sided cages
Host
Molecules
Guest
Molecule
EG55F8 Flow Assurance
MSc in Subsea Engineering
Wax
Wax is formed from long chain paraffins
and naphthenes
Wax crystals precipitate out of solution at
low temperatures
The wax appearance temperature (WAT)
or cloud point is the temperature at which
wax crystals first appear
Wax can only deposit if the pipe wall is
below WAT
The pour point is the lowest temperature at
which the oil can be poured under gravity
A yield force is required to start fluids
flowing if temperature is below the pour
point
EG55F8 Flow Assurance
MSc in Subsea Engineering
Wax Deposition
Wax solidifies if the fluid temperature is below WAT
Wax crystals will remain suspended unless there is a
temperature gradient
Deposition of wax changes the fluid composition at the
wall
Wax will harden over time because of concentration
gradients
The upstream few kilometres of an uninsulated pipeline
are most susceptible to wax
WAT
T
bulk
T
wall
Solid wax phase
precipitates on wall
Concentration gradient in
fluid as heavy molecules
solidify drives light
molecules away from wall
WAT
T
inlet
T
ambient
EG55F8 Flow Assurance
MSc in Subsea Engineering
Asphaltenes
Dark brown or black solids that precipitate in
the presence of n-pentane or n-heptane
Asphaltenes are solid particles in a
dispersed phase within the oil
Flocculate (come out of suspension) as a
result of
Pressure drop
Gas lift (with rich gas)
Mixing of incompatible oils
Asphaltenes do not melt
Flocculation may be irreversible
Highly soluble in aromatic compounds
(xylene)
Asphaltenes are stabilised by the presence
of resins
EG55F8 Flow Assurance
MSc in Subsea Engineering
Other Issues
Corrosion (covered in depth elsewhere)
Principally results from CO
2
dissolved in water
(carbonic acid) or by-products of bacterial
activity (microbially influenced corrosion)
attacking mild steel.
Scale
Mineral deposits (carbonates and sulphates)
resulting from reductions in solubility with
changing P and T.
Also occurs when incompatible water streams
are mixed (e.g. injection water plus formation
water
Mitigation requires injection of inhibitors and/or wash water
Salt
Halides (commonly sodium chloride) can deposit in significant quantities, particularly
as a result of evaporation or if MEG injection reduces solubility.
May require injection of wash water (clean desalinated water) to dilute produced water.
EG55F8 Flow Assurance
MSc in Subsea Engineering
Other Issues
Solids
Solids (sand and debris) will
deposit along with wax if
velocities are insufficiently high
Bottom solids provide sites for
microbial growth (and
subsequent corrosion)
Physical removal by pigging is
the only assured solution
Emulsions
Water and oil phases can form
stable emulsions if there is
sufficient mixing in the presence
of emulsifying agents.
Emulsions make the fluids non-Newtonian
Generally, emulsions are more of a problem for
processing, but can make transportation over
long distances less predictable.
EG55F8 Flow Assurance
MSc in Subsea Engineering
Summary
Unprocessed well fluids are a mix of gas, oil, wax, asphaltenes, resins,
water, salts, solids and production chemicals.
At flowing pressures and temperatures, most unprocessed fluids will be
multiphase.
Maintaining stable multiphase flow through field life can be difficult, if not
impossible, and requires careful selection of pipeline size and number of
pipelines.
Changes in conditions along a pipeline system can lead to the formation of
solids, which can cause blockage.
Maintaining a blockage free system requires careful control of fluid
pressures and temperatures through field life.
Unprocessed fluids can be highly corrosive, and require exotic materials or
inhibitor chemicals for transportation.
EG55F8 Flow Assurance
MSc in Subsea Engineering
i
r
l
o
T
i
T o
r
q
One dimensional conduction equation:
t
T
c q
r
T
kr
r r c
c
= +
|
.
|

\
|
c
c
c
c

v
1
r
T
k
r l
q
c
c
=
t 2
Fourier law of heat conduction:
Steady state, no q
v
, constant k:
0 =
|
.
|

\
|
c
c
c
c
r
T
r
r
( )
( )
i o
i
o i
i
r r
r r
T T
T T
ln
ln
=

( )
R
T T
q
o i

=
( )
k l
r r
R
i o
t 2
ln
=
where:
Conduction in Cylindrical Shells
EG55F8 Flow Assurance
MSc in Subsea Engineering
i
r
l
1
T
2
T
o
T
i
T
1
r
2
r
o
r
q
Conduction in Concentric Shells
o o
T T q R =
2 2
1 1
T T q R
i i
=
( )
o i o i
T T q R R R = + +
2 12 1
2 1 12
T T q R =
Fourier law of heat conduction:
Heat transfer (excluding fluids):
o i t
T T q R =
( )
o i
T T UA q =
ref
( )

=
=
n
m m
m i m o
k
r r
l
A
U
1
2
ln 1
t
ref
where:
Normally A
ref
is the outside area of the steel pipe, but should always be explicitly stated.
EG55F8 Flow Assurance
MSc in Subsea Engineering
l
q
f
T
a
T
o
T
i
T
Inside/outside boundary layers:
Overall heat transfer (including fluids):
Inside and outside film coefficients can
be estimated from empirical correlations.
( )
a o o o
T T A h q =
( )
i f i i
T T A h q =
a f
o o
t
i i
T T q
A h
R
A h
=
|
|
.
|

\
|
+ +
1 1
( )
a f
T T UA q =
ref
( )
|
|
.
|

\
|
+ + =

= o o
n
m m
m i m o
i i
h d k
r r
h d l
A
U
1
2
ln 1 1
1
t
ref
where:
Overall Heat Transfer Coefficient
Units for U are Watts per square metre per Kelvin (W/m
2
/K).
EG55F8 Flow Assurance
MSc in Subsea Engineering
( )
|
|
.
|

\
|
+ + =

= o o
n
m m
m i m o
i i l
h d k
r r
h d U
1
2
ln 1 1 1
1
t
where (theoretically):
Heat Transfer per Unit Length
For composite systems (i.e. flexible pipes) A
ref
is not
always easily defined, but:
( ) l U l U d A U
l
= =
ref ref
t
where U
l
is commonly referred to as the heat transfer
coefficient per unit length.
In this case:
( )
a f l
T T l U q =
Units for U
l
are Watts per metre per Kelvin (W/m/K).
Do not confuse OHTC and HT per unit length always check units and A
ref
.
EG55F8 Flow Assurance
MSc in Subsea Engineering
Heat Loss in Pipelines
Heat loss from fluid:
x
dx
dT
c m x
dx
dT
T T c m dq
f
p
f
f f p
o o =
|
|
.
|

\
|
|
|
.
|

\
|
+ =
Heat loss through wall:
( )
a f
T T U x d dq = o t
ref
Temperature decays exponentially, if fluid properties and OHTC are constant
( )
a f
p
f
T T
c m
U d
dx
dT
=

ref
t
x
c m
U d
a f
a f
p
e
T T
T T

ref
1
t

Equate heat loss and integrate:

f
T
x
dx
dT
T
f
f
o +
x o
dq
x
m
1
f
T
EG55F8 Flow Assurance
MSc in Subsea Engineering
Pipeline Insulation Systems
Insulation systems are classed as WET or DRY, depending on whether the
insulation is contained inside a structural carrier pipe
Solid insulating material
(at ambient pressure)
Anti-corrosion
coating
Pipeline
External hydrostatic pressure transmitted
through insulation (liable to crushing)
Anti-corrosion
coating
Pipeline
Typical Wet Insulation System
Carrier Pipe
Foamed or blanket wrap
insulating material (at or
below atmospheric
pressure)
External hydrostatic pressure
taken by carrier pipe
Typical Pipe-in-pipe Insulation System
EG55F8 Flow Assurance
MSc in Subsea Engineering
Wet Insulation Systems
Deepwater wet insulation is typically based on syntactic
polyurethane (SPU).
SPU is solid PU containing a matrix of microscopic low
conductivity microspheres.
Microspheres are typically ceramic for moderate depths (low
conductivity but relatively poor collapse resistance) and glass
for extreme depths.
Theoretically applicable in depths down to 2800m
Limited maximum temperature at about 115C
Alternatives can be based on composite polypropylene
(PP) systems
Composed of a layer of foamed PP surrounded by a thick
layer of solid PP
PP has higher operating temperature at about 155C
Typical OHTCs in the range 2.0 to 3.5 W/m
2
/K
Bredero Shaw ThermoFlo SPU system
Bredero Shaw Thermotite PP system
Major suppliers include Dow Hyperlast, Bredero Shaw and EUPEC
EG55F8 Flow Assurance
MSc in Subsea Engineering
Deepwater Wet Insulation
Bredero Shaw
Thermotite PP system
EG55F8 Flow Assurance
MSc in Subsea Engineering
Dry Insulation Systems
Dry insulation must be contained in a
structural carrier pipe
Carrier pipe must be watertight and
collapse resistant
Annulus may be at or below atmospheric
pressure
Insulating materials include:
polyurethane foam (Logstor, Bredero Shaw,
EUPEC)
microporous silica blanket wrap (Aspen
Aerogels, Cabot, InTerPipe)
mineral wool (Rockwool)
Microporous and mineral wool based
materials offer low OHTC and high
temperature service
OHTC ~0.7 W/m
2
/K
Max temperature >200C
Aspen Aerogels Pyrogel
Cabot Nanogel
compression packs
fitted in pipe-in-pipe
system
EG55F8 Flow Assurance
MSc in Subsea Engineering
Heated Flowline Concepts
Two basic concepts for heating a subsea flowline
Convective heating or Hot Water systems
Electrical heating
Hot water systems can be direct or indirect
Direct heating systems have the heating medium flowing round the outside of the
production pipe (annulus heated systems)
Indirect heating systems have heating pipes bundled with production pipes in a
common carrier
Electrical systems may also be direct or indirect
Direct Electrical Heating (DEH) relies on pipeline steel carrying the heating
current
Indirect heating systems use induced currents in the pipeline or direct thermal
contact with electrically heated cables
EG55F8 Flow Assurance
MSc in Subsea Engineering
Direct Hot Water Heating
Production Flowline (14-inch )
Insulation (13mm)
Carrier Pipe (37-inch )
Heating Medium Supply (12-inch )
Heating Medium Return
Test Flowline (8-inch )
Methanol Service Line (3-inch )
Heating Medium Supply
Insulation
Jacket Pipes (12-inch )
Production Flowline 1 (8-inch )
Heating Medium Return
Production Flowline 2 (8-inch )
Britannia Bundle (NS), 15km:
King Flowline Loop (GoM), 2 x 27km:
EG55F8 Flow Assurance
MSc in Subsea Engineering
Production Flowline
Heat Transfer Medium
Insulation
Jacket Pipe
Production Fluids
Heating Medium
Heating Medium Supply/Return Flowlines
Indirect Hot Water Heating
Carrier Pipe (40-inch )
Gas Injection (8-inch )
Electro-hydraulics
Methanol (2-inch )
Sleeve Pipe (40-inch )
Insulation
Heating Medium Return
(2-inch )
Heating Medium Supply
(3-inch )
Heat Sensor
Heat Transfer Medium
Production Flowline
(8-inch )
Production Flowline
(6-inch )
Kessog Single Flowline Option
Gullfax Phase 1 Bundle
EG55F8 Flow Assurance
MSc in Subsea Engineering
Electrically Heated Systems
Systems can be Direct Electrically Heated (suitable for single pipe and pipe-
in-pipe systems) or Indirect Electrically Heated (suitable for bundled
applications)
DEH systems include:
Closed Loop Single Pipe (grounded and ungrounded)
Open Loop Single Pipe
Pipe-in-pipe (centre feed and end feed)
IEH systems include:
Tube Heating (induction and conduction)
Trace Heating
Open loop single pipe DEH is field proven for long North Sea tie-backs
sgard (8.5km), Huldra (16km) , Kristin (6.7km), Norne (9km),
Tyrihans (43km)
Pipe-in-pipe DEH systems are field proven in deep water GoM
Serrano (6km), Oregano (7.5km), Habanero (17km), Na Kika (section lengths
2km to 13km)
EG55F8 Flow Assurance
MSc in Subsea Engineering
Single Pipe DEH Systems
Single Phase AC Power Supply
Isolation Joint
Electrical Cable
Closed Loop Ungrounded DEH
Single Phase AC Power Supply
Electrical Cable
Closed Loop Grounded DEH
Single Phase AC Power Supply
Electrical Ground
Electrical Cable
Open Loop DEH
Isolation Joint
Isolation Joint
Electrical Ground
Electrical Ground
Non-hydroscopic Thermal
and Electrical Insulation
Non-hydroscopic Thermal
and Electrical Insulation
Thermal Insulation
EG55F8 Flow Assurance
MSc in Subsea Engineering
Pipe-in-pipe DEH Systems
Single Phase AC Power Supply
End Feed Pipe-in-pipe DEH
Isolation Joint
Dry Pipe-in-pipe Thermal
and Electrical Insulation
Bulkhead (Electrical Connection)
Single Phase AC Power Supply
Centre Feed Pipe-in-pipe DEH
Dry Pipe-in-pipe Thermal
and Electrical Insulation
Bulkhead (Electrical Connection)
Bulkhead
EG55F8 Flow Assurance
MSc in Subsea Engineering
Indirect EH Systems
Three Phase AC Power Supply
Electrical Common
Induction Tube Heating
Conduction Tube Heating
Thermal Insulation
Ferromagnetic Tube (x3)
Supply Cables (x3)
3x Single Phase AC Power Supply
Conducting Metallic Tube (x3)
Thermal Insulation
Trace Heating
Three Phase AC Power Supply
Heating Cables (multiples of 3)
Thermal Insulation
Electrical Common
EG55F8 Flow Assurance
MSc in Subsea Engineering
Operational Issues
The principal objective for the Flow
Assurance Engineer is to deliver and
maintain an operable system
Systems must reliably:
start-up with wells and pipelines hot or
cold, depressurised or liquid flooded,
ramp-up and ramp-down without
flooding platform based receiving
plant,
shut-down without over-pressurizing or over-heating pipeline systems,
blow-down to safe pressure in a practical time frame without flooding flare systems,
maintain performance throughout field life.
Hydrate blockages on start-up of deep-water systems are very high risk
it may not be possible to sufficiently reduce pressures in deep water to dissociate
hydrates a blockage can potentially write off a subsea pipeline (>$300MM)
A hydrate management strategy is required
EG55F8 Flow Assurance
MSc in Subsea Engineering
Operating Strategies
Continuous chemical inhibition
Thermodynamic inhibitors: methanol (MeOH) or
mono-ethylene glycol (MEG).
Low dosage hydrate inhibitors (LDHI):
anti-agglomerates (AA) or kinetic inhibitors (KI).
MeOH and MEG
May be used on a continuous basis, but must be
recovered from the produced fluids to be economically viable.
MeOH is highly flammable and is distilled out of the water phase: significant
amounts of MeOH partition into the gas phase and are lost.
MEG is more viscous and heavier (requires larger diameter supply pipeline) and
is not effective at start-up or for hydrate remediation (no partitioning to gas
phase).
methanol
mono-ethylene glycol
MeOH used in oil dominated systems.
MEG preferred for gas dominated systems (particularly if
continuous injection required), but MeOH also required for start-up.
Large quantities of either chemical is required: typically 3-inch to 6-
inch supply lines.
EG55F8 Flow Assurance
MSc in Subsea Engineering
Operating Strategies
LDHI
Kinetic inhibitors slow the crystallization of
hydrates but do not provide long term
protection during shut-down.
Anti-agglomerates prevent crystals from
sticking together and growing to form a
potential blockage.
Only small quantities required; may be
delivered through conventional umbilical cores
( -inch or -inch)
Require extensive lab testing and difficult to
predict effectiveness
Oceaneering Multiflex electro-hydraulic umbilical
EG55F8 Flow Assurance
MSc in Subsea Engineering
Operating Strategies
Intermittent chemical injection
Relies on injection of bulk chemicals before
start-up and shut-down.
Reliable providing temperatures are kept
high during normal operation.
Requires insulated or heated pipelines.
Unplanned shut-down (with no bulk
chemicals in the system) represents a
significant problem.
No touch time - blow-down and dead
oil displacement
Passive insulation cannot prevent hydrate/wax blockage indefinitely.
Insulation requirement defined by the required no-touch time.
Pipelines must be blown-down to below hydrate formation pressure or hydrate
forming fluids must be displaced before temperatures become critical.
SIGNIFICANT LOST REVENUE FROM LONG PIPELINES - FLARING.
Dead oil (or diesel) displacement may be the only option for long, deep pipelines,
but requires a large diameter service pipeline.
EG55F8 Flow Assurance
MSc in Subsea Engineering
Practical Considerations
Subsea temperature transducers do
not measure bulk fluid temperature
The sensor is encased in a
conducting paste within a thermo-
well
The thermo-well is mounted in a tee
and set back from the pipeline wall
The thermo-well is usually stainless
steel with poor conductivity
The tee is often uninsulated and
close to seabed temperature
The temperature off-set may be
anything up to 15C
Welded Tee
Thermo-well
Pipeline
Temperature
Sensor
Insulation
EG55F8 Flow Assurance
MSc in Subsea Engineering
Practical Considerations
Subsea pressure transducers are (often) offset through impulse lines
May be mounted on uninsulated double-block-and-bleed units
Small diameter impulse lines are extremely vulnerable to blockage
Pressure
Transducer
Mounting
Face
Pipeline Tee
Mounting
Face
Impulse line
Bleed line
EG55F8 Flow Assurance
MSc in Subsea Engineering
Key Messages and Conclusions
Production fluids are very complex and can block (or restrict) flow:
Multiphase flow requires careful sizing of pipeline and first-stage separator and
can give rise to fatigue issues in unsupported pipework (risers)
Hydrates high temperatures or bulk chemical injection required, leading to
insulated or heated systems and blow-down or dead-oil displacement strategies
for long term shut-down
Wax high temperatures and pigging strategy should be maintained (sometimes
inhibitor chemicals)
Asphaltenes careful design to avoid precipitation or chemical treatment
Scale chemical injection required
Salts wash water service line
Corrosion chemical injection or material selection issues, plus long term
inspection strategies (intelligence-pigging)
Solids pigging strategy (round-trip pigging or subsea launchers)
EG55F8 Flow Assurance
MSc in Subsea Engineering
Key Messages and Conclusions
Flow assurance drives architectures and layouts:
One, two or more production pipelines (slugging, round-trip pigging, dead oil
displacement, late field life turn-down)
Pipeline design (wet insulation, pipe-in-pipe insulation, heated pipelines)
One, two or more service pipelines (lift gas, wash water, dead oil supply, venting
for hydrate remediation)
Umbilical chemical cores (scale inhibitor, corrosion inhibitor, wax inhibitor, LDHI)
Manifold functionality (temporary or permanent pig launch facilities, vent
arrangements for depressurisation)
EG55F8 Flow Assurance
MSc in Subsea Engineering
Questions?
BHP Billiton Atlantis Production Facility, 2000m Water Depth, Gulf of Mexico