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DAY 1
FMC
Tine Bauck Irmann-Jacobsen
Week 41, 8th October 2012
Agenda
Day 1 8th Oct
Subsea compression
Multiphase pumping
Separation
Exercises
Traditional approaches are inappropriate for deepwater production due to extreme distances, depths, temperatures or
economic constraints.
The term Flow Assurance was first used by Petrobras in the early 1990s in Portuguese as Garantia do Escoamento
(pt::Garantia do Escoamento), meaning literally Guarantee of Flow
Handling solid deposits, such as, gas hydrates, asphaltene, wax, scale, and naphthenates.
Critical task during deep water energy production because of the high pressures and low temperature involved.
Solid deposits can interact with each other and can cause blockage formation in pipelines and result in flow assurance
failure.
The financial loss from production interruption or asset damage due to flow assurance mishap can be astronomical
detailed design, surveillance, troubleshooting operation problems, increased recovery in late life etc., to the petroleum
flow path (well tubing, subsea equipment, flowlines, initial processing and export lines).
Risers
Subsea process equipment
Manifold and Flowlines
Wells
Field example
Types of field
Oil/Gas fields
Old fields: Increased Oil Recovery
New fields: Standard fields/ Difficult accessible fields
FEED
Detailed
Engineering
Operation
Tail end
production
Operational philosophy
Waxes
Emulsion
Corrosion
Asphaltenes
Flow Induced Vibrations
Water hammer /pressrue
surges
Multiphase simulations
Process equipment
SYSTEM SOLUTIONS
The engineering process
Subsea station design
Steady state simulations
System solution and design
Hardware selection and design
Topside
Operational philosophy
Field layout
Riser
- Startup/shutdown
Well location
- Flow assurance strategy
Manifold location
Dynamic simulation - verify solution
Flow line / Riser system
Technology Maturity/Qualification assessment
Water depth /step-out distance
Topside
Layout
Restrictions
Requirements
Pipeline
Flow Assurance
Wells
Slugging
Safe shutdown and restart
Hydrate
Wax
Sand
Scale
Near well reservoir
Reservoir data
Production profile
Flowrates
Densities
GVF
Viscosities
etc
Reservoir data
Gas/water quality requirements
Monitoring requirements
FLOW MANAGMENT
Operation
Shutdown:
- Cooldown and no-touch-time
- Depressurisation
- Liquid drainage of flowlines
Surveillance
Topside
Hydrate Management
Sensor reconciliation
Riser
Optimization
Real time reservoir management
Wells
Production rates
Near well reservoir
(b means bulk)
Wax / Asphaltenes
Emulsion / Foam
Scale
Gas Hydrates
Corrosion
14
Increased liquid
accumulation and
pressure drop
Large water slugs disturb
process
Corrosion
Multiphase flow
splitting
Velocities
Sand
Erosion
Flow Induced Vibrations
Temperature control
Design/Subsea Cooling
Terrain slugging
Can cause large pressure swings
Slug catchers and receiving separators are voluminous and heavy
equipemnt that drives the cost
Hydrodynamic slugging
17
Water Hammer
is a pressure surge or wave resulting when a fluid (usually a
liquid but sometimes also a gas) in motion is forced to stop or
change direction suddenly (momentum change). Water
hammer commonly occurs when a valve is closed suddenly at
an end of a pipeline system, and a pressure wave propagates
in the pipe. It may also be known as hydraulic shock
Remediation means
Pipeline sizing
Design of Chemical
Injection Systems
Thermal Insulation
Design
Choke design
Erosion analysis
Flow assurance is
to take precautions to
Ensure Deliverability
and Operability
300
Depressurization
250
Insulation of pipelines
Heating
New technology
Cold flow
Pressure [kgf/cm]
200
150
100
Wellfluid
50
0
0
T = 4C
10
15
Temperature [C]
20
25
Remediation means
48 vol%
MEG
38 vol%
MEG
200
19 vol%
MEG
wellstream
Pressure [bara]
180
160
no inhibitor
140
20 wt% MEG
120
40 wt% MEG
100
80
50 wt% MEG
60
60 wt% MEG
40
20
0
-20
-15
-10
-5
10
15
20
25
Temperature [C]
WAX management
Wax control:
Insulation
Scraping (pigging)
17C @
Steel support 21hrs
Thin peek layer of
on the steel support
increased the
thermal performance
23C @
21hrs
Steel support with peek
24
Heat transfer-insulation
Calculation of heat transfer 1
Q is total heat exchange
is mass rate kg/s
Cp is heat capacity
is loss of temperature over subsea station
Inclination
Rate manipulation eg. Gas lift, always production above min flow
Min flow: Min rate before velocity
Simulation modeling
Slugging require transient model
8 ID Pipe:
20 m3/h = 0.17 m/s
30 m3/h = 0.25 m/s
40 m3/h = 0.34 m/s
6 Pipe:
20 m3/h = 0.31 m/s
30 m3/h = 0.46 m/s
40 m3/h = 0.61 m/s
50 m3/h = 0.73 m/s
2800
2400
2000
1600
1200
800
400
Oil-rsm
Oil-Maxpro
2016
2015
2014
2013
2012
2011
2010
2009
2008
2007
0
2006
3200
2005
HYSYS dynamic
3600
FLOW MANAGMENT
FlowManager integrates flow calculations
through the entire production system
giving a common monitoring, planning and
optimization tool for the operator. Possible
coupling with Eclipse, Olga, Hysys etc
FlowManager
(default)
FlowManager Dynamic
or OLGA (option)
FlowManager
(default)
FlowManager
Dynamic or
OLGA (option)
FlowManager
Dynamic
FlowManager
(default)
FlowMangerTM
Near-well model
or
Coupling to
Eclipse (option)
Custom
Office ne
Onshore
E.g. OPC DA
On site
CPM system
Topside
Data
Data
Provider Provider
# 2
# 1
Data
Provider
# n
FMC Data
Riser
Data
Access
Pipeline
Historic
Databas
Wells
Near well reservoir
Data
Source
# 2
Data
Source
# n
Next week
Exercises are in the compendium
Exercise 1: Minimum flow criteria to keep Subsea Process outside
hydrate formation area
Exercise 2: Heat losses over a long pipe section
Exercise 3: Effect on pressure when enclosed system is cooled down
Exercise 4: Head loss and pumping requirements in flowlines
Exercise 5: Well head pressure at shut-in conditions