Subsea processing

Oslo 8. September 2011 Hvard Eidsmoen, Statoil

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Content

Introduction/Motivation Why subsea processing? Overview of technologies, applications and examples Boosting Separation Compression Raw seawater injection Other important systems Power supply considerations Technology needs
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Development from platforms to subsea to beach

Gravity based platforms (limited water depth) - Ekofisk

Platform wells Single phase export lines (separate lines for gas and oil)
Gravity based or floating platforms (increasing water depth) - Statfjord

Subsea wells (increasing area one platform can drain) Single phase export lines (separate lines for gas and oil)
Gravity based or floating platforms - Troll

Picture by Statoil

Multiphase export line (reducing platform size through smaller process)

Subsea to beach (eliminating platform) Snhvit/Ormen Lange

Subsea wells Multiphase pipeline directly to shore (increasing distance with time)
Subsea processing sgard

Increasing the efficiency of subsea production systems

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Subsea in Statoil
Today more than 50% of Statoil production is from
Subsea production systems.

Statoil operates approximately 480 subsea wells New development prospects are dominated by; Subsea tie-ins to existing infrastructures Subsea deep water developments at remote
locations

In 2010 more than 50% of the Norwegian production

was from subsea wells

Subsea processing is a tool to enable new

developments and increase the recovery factor

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Different challenges around the world Need a large toolbox

Arctic: Remote locations and hostile environment

NCS: Shallow water and aging infrastructure

SEA: Deep water and limited infrastructure GoM: Ultra deep water and deep reservoirs

Brazil: Heavy oil and deep water

Angola: Deep water and no infrastructure

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Future possibilities in Statoil portfolio

Norwegian Continental Shelf (NCS): Tail end production lower pressure and higher water cut

Remote areas Lack of existing infrastructure

Existing infrastructure with space, weight and

time limitations

Likely to be long tie-backs Possibly harsh environment

Smaller discoveries?
Gulf of Mexico (GoM) Tight reservoir

High shut-in pressure Deep-/Ultra-deep water

Brazil/West Africa Deepwater

Heavy oil Lack of infrastructure for gas

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Pressure drops in the system

PSEP

PFWH

PRB

PFBH

PRES

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Pressure drops in the system

PFBH-PRES: Pressure drop in reservoir and near wellbore zone. Mostly determined by
reservoir parameters and can be very large

PFWH-PFBH: Pressure drop in wellbore. For oil wells dominated by gravity and for gas wells
dominated by friction

PRB-PFWH: Pressure drop in pipeline. Usually dominated by friction. PSEP-PRB: Pressure drop in riser. For oil systems dominated by gravity and for gas systems
dominated by friction

PRES Reservoir pressure PFBH Flowing bottom hole pressure PFWH Flowing wellhead pressure PRB Riser base pressure PSEP Separator pressure
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Oil vs gas reservoirs

Gas reservoir Oil reservoir

Gas cap*

Oil zone where production is done

Water zone*

Gas reservoir can be viewed as closed in volume of gas, where the pressure decreases as the gas is drained.

Gas cap will help maintain pressure as oil is produced. Associated gas will be produced from oil below bubble point. Water zone will provide pressure support. * Not always present

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Typical production profile (oil field)

2 Oil

Production rate

Gas Water 1

Rapid increase in water production after water break through. Production limited by topsides process facility.

0 0 5 Time 10 15

Oil production decreases with reservoir pressure

Gas production increase due to gas cap (towards end of field life) and release of associated gas

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Accumulated production (oil field)

50 45
Accumulated production

40 35 30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9

Oil Gas Water

Minimize water production -Environmental considerations -Limit process facility

Maximize hydrocarbon recovery

10 11 12 13 14 15 16

Year

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Parameters influencing the development solution

Reservoir parameters (porosity, permeability, etc) Depth of reservoir (length and height of well) Water depth (height of riser) Gas oil ratio (GOR) (average density of fluid) Water production (average density of fluid) Step-out length (distance from well to platform) Diameter of wellbore Diameter of pipeline Separator pressure

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What do we do to increase the recovery

Additional wells Riserbase gas lift Lower density of column in riser reduced pressure drop Bottom hole gas lift Lower density of column in well and riser reduced pressure drop Additional gas increases frictional pressure drop Water injection Replacing the produced volumes maintains the reservoir pressure Water production will increase with time Reduced separator pressure
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What is subsea processing?

Manipulating the well stream between wellhead and host.

Subsea processing applications are:

Hydrocarbon boosting (pumping) Separation systems Raw seawater injection Gas compression

Prerequisites and enablers for the above

applications:

Long distance / high voltage power Advanced process monitoring and control Cost-efficient installation, maintenance and retrieval

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Subsea processing one example

Gas riser

Oil riser

Umbilical riser

Separator

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Why Subsea processing?

Increased productivity and recovery Reduced investments, operating costs and increased revenue Improved flow assurance Longer tie-back distances HSE Less offshore personnel Less materials Less emissions Less to decommission

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Pump system

Production riser

Umbilical riser

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Hydrocarbon boosting

Pressure

Pump close to wellhead enables Reduced wellhead pressure Increased drawdown (lower
bottom hole pressure)

Riserbase

Wellhead

More pressure to push production

to platform
Distance Original pressure profile With pressure boosting

What can be achieved (technologies

will be reviewed in later lecture)

50 to 100 bar for multiphase

production

200+ bar for single phase (~2000

m water column)
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Pump sizing example

Power requirement for a single phase pump: 20000 bbld/d of liquid (3180 m3/d) 100 bar pressure boost Pump efficiency = 0.75 P [W] = Q [m3/s] * dP [Pa] / Efficiency P [W] = 490000

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Boosting Lufeng (1997)

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Boosting experience - Lufeng

Business case General experience

Artificial lift: enabler for field development World first very positive. Design life 7 years. Expected life 3-5 years, but shut in after 12.

Issues

Mechanical seals (in operation, also in transit) Penetrator Control system (air conditioning!) Electrical connectors (beyond design life)

Lessons learned and applied

Improved testing and qualification procedures. Improved / more robust component designs.

Further boosting experience is detailed under Troll Pilot / Tordis / Tyrihans.

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Subsea separation applications

Remove water at wellhead Reduced water production reduces pressure drop in pipeline to platform Can enable increase in production if topsides facility is bottleneck Water injected for disposal (or pressure support) Gas liquid separation at riser base Production in separate gas and liquid riser More efficient boosting for single phase liquid Separation to send gas and liquid to different facilities

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Separation and boosting system

Production riser

Umbilical riser

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Separation experience Troll Pilot

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Production profile with water separation and reinjection

2
Production rate
Oil Gas Water

Reduction in water production

1

0 0 5 Time 10 15

Increase in oil and gas production due to reduced wellhead pressure

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Separation Troll Pilot (2000)

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Separation experience Troll Pilot

Business case

Increased hydrocarbon production and recovery Currently injecting ~20 000 bbls/day of produced water 10 yrs after installation

General experience

World first separation and produced water reinjection system Robust separator design. No sand jetting necessary to date Stable operation and near 100% uptime from 2008

Issues

Electrical connector (start up) Water ingress to motor due to system design Inductive level instrument (prototype / backup solution)

Lessons learned and Improved component design and test / qualification procedures applied Improved barrier fluid system design

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Separation and boosting Tordis (2008)

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Separation experience - Tordis

Business case General experience Increased hydrocarbon production and recovery through water reinjection (debottlenecking) and multiphase hydrocarbon boosting World first application of produced water reinjection with sand management, multiphase metering, multiphase boosting of wellstream fluids. Modular design Successful start up and operation for 4 months (then bypassed due to injection well issue). Multiphase pump restarted October 2009 for 3 months. System modifications currently underway. Issues Challenging tie-in to existing control system. Challenging connection of umbilical barrier fluid supply Gas evolution (topsides) from new power umbilical Multiphase meter start up & calibration. Acoustic leak detection Lessons learned and applied High speed communications preferable where sophisticated instrumentation is utilised (applied on Tyrihans)

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Separation experience - Tordis

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Pazflor Gas liquid separation

Riser to platform

P C

LC

Multiphase Gas From wellhead Liquid

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Pazflor Gas liquid separation

Start-up 2011 (operated by Total Statoil
~24%)

33

Enables production from Miocene reservoir at

800 m water depth

Gas /liquid separation Liquid boosting 2.3 MW hybrid pumps Pumps tolerate gas Vertical Separator design minimal gas carry under Sand removal through liquid line Gas free floating to FPSO

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Separation qualities

Separation system must meet requirements from downstream systems Water reinjection Typically 1000 ppm oil in water Gas liquid separation for efficient oil boosting 5 t0 10 vol % gas in liquid Gas scrubbing systems Liquid in gas determined by application Protection of downstream compressor Downstream flow assurance solution
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Sand handling

Maximum sand production is typically 10 ppm by weight Sand type and size distribution varies between fields Problems caused by sand Pumps/compressors will be worn out Separators will fill up 10000 m3/d of liquid with 10 ppm of sand 100 kg/d of sand 30 to 40 tons per year

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Compression

Compression is the most recent subsea processing technology Not yet implemented in any field worldwide Compression is comparable to pumps but used for fields with mostly gas Typically a few volume % liquid Traditional topsides compressors have low tolerance for liquid, resulting in two
approaches to subsea compression

Separate gas so that a traditional compressor can be used Build a liquid tolerant or multiphase compressor

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Subsea compression development

Field Planned Installed Design life (yrs) Depth (m) Tieback (km) No of units Pressure boost (bar) Power (MW) VSD

Gullfaks 2014 20 135 15 2 30 10 Topside

sgard 2015 30 260 40 2 50 20 Topside

Ormen Lange

30 850 120 4 60-70 58 Subsea

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Subsea compression development

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Subsea compression development

Gas Production Length Width Height Total weight 70 meters 54 meters 25 meters 6000 Tons Condensate Production Electrical Power Demand Target Availability

60 MSm3/d 7200 Sm3/d 58 MW 97.5%

Ormen Lange is operated by Shell

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Subsea compression example

Need for compressor with: 40 bar pressure boost 5 MSm3/d gas flow rate 50 bar compressor suction pressure (pressure ratio is important) 40C inlet temperature Power requirement 5.3 MW Outlet temperature 100C

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Why subsea seawater injection

Space and weight is at a premium at existing platforms Difficult to fit a water injection system weighting several hundred tons New discoveries ar often tied back to existing platforms some distance away Pipeline can be expensive Different water types can not be mixed in injection systems Sea water Produced water

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Raw seawater injection system

Production riser

Umbilical riser

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Subsea raw seawater injection Tyrihans (2010)

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Subsea raw seawater injection experience - Tyrihans

Business case

Increased oil recovery through combination of gas and water injection, using subsea raw seawater injection for the first time in Statoil. Estimated IOR of 10% from subsea RSWI Powerful subsea injection system, utilising 2 x 2.5 MW pumps Topsides modifications plus pump system onshore wet testing carried in 2008. Pumps installed 2009. Well completion and system start up due in Q4 2010 Fault tolerant condition monitoring system and high speed communications

General experience to date

Issues Lessons learned and applied

Challenging control system interfaces (solved by good cooperation between key suppliers and operator) High speed fibre optic comms system (TCP/IP data transmission) learning from Tordis

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Other important parts

Advanced process monitoring and control Subsea processing has much higher monitoring needs than traditional
subsea systems Shorter response time More sensors More complex sensors

Cost-efficient installation, maintenance and retrieval Large parts to be installed Need for retrieval when parts break or wear out Regular inspection

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Other important parts

Long distance power transfer

Step-out distance below 15 to 20 km Power transfer at ~7 kV with topsides VSD Examples: Troll Pilot, Tordis SSBI Step-out distance ~20 to ~80 km Power transfer at 22 to 52 kV with topsides VSD Topside step-up and subsea step-down transformer required Examples: Tyrihans, sgard Subsea Compression, Step-out distance above ~80 km Power transfer at 132 kV and 16 2/3 Hz (for reduced power loss) Subsea VSDs and power distribution Example: Ormen Lange
Possible step-out distances will depend on power requirement and number of units

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Power and control umbilical

One three phase high voltage (HV)

circuit per pump/compressor

Barrier fluid (one line per

pump/compressor + one spare)

Fibre optics LV power Hydrate inhibitor Possibility of combining with control

umbilical for subsea system should be examined

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Technology needs

Pumps: Higher hydrostatic pressure

Larger capacities (volume, head, higher viscosities, gas

tolerance)

Larger motors Reduced weight and size of topsides systems

Separation From 300 to 3000 m water depth compact technology/in-line separation

From normal fluids to viscous oils electrostatic

coalescence

From bulk separation to export qualities

Compression Simplified systems wellstream compression

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Discussion on economy

Value of increased production Development cost Operational expenses Other considerations

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Assignment
Platform A: Process capacity for oil, but only very limited water capacity. Some power available 10 km Platform B: Available process capacity for oil and water. Plenty of power available.

30 km

Oil discovery: 10 MSm3 of oil 300 m water depth 5000 m3/d of oil and 5000 m3/d of water

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Literature

Offshore Magazine. Review poster of subsea procesing projects http://www.offshore-mag.com/etc/medialib/platform-7/offshore/mapsand_posters.Par.84540.File.dat/SubseaProcessing-030311ADs.pdf

OTC 20619 Experience to Date and Future Opportunities for Subsea Processing
in Statoil, Simon Davies and William Bakke, Statoil ASA; Rune Mode Ramberg and Roger Oen Jensen, Statoil Gulf of Mexico

OTC 20261 Subsea Power Systems a Key Enabler for Subsea Processing,
Steinar Midttveit, Bjarne Monsen, Snorre Frydenlund, Karl Atle Stenevik, Statoil ASA.

OTC 18749 The Tordis IOR Project, Ann Christin Gjerdseth, FMC Technologies
and Audun Faanes and Rune Ramberg, Statoil

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Thank you
Title: Name: Title: E-mail: www.statoil.com

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