First World Wide Subsea Raw Seawater Injection System …possibility.no/utc2008/ps/G3 Nils...

First World Wide Subsea Raw SeawaterFirst World Wide Subsea Raw SeawaterInjection System in Operation on CNR’s Columba E FieldInjection System in Operation on CNR’s Columba E Field

Nils J. Vågen

Framo Engineering

Columba E – First Raw Seawater Injection System

• PROTECTIVE STRUCTURE & FRAMO DUAL PUMP STATION INSTALLED MAY 2006

• PUMPS DELIVERED JUNE 2007

START UP JULY 2007• START-UP JULY 2007

Framo Dual Pump Station PROTECTIONStation PROTECTION

STRUCTURE

SUBSEA RAW SEAWATER INJECTION SYSTEM

Pump Power and Control System

A cost effective alternative to ti l t id tconventional topside water

injection system

Umbilical

Water Injection Pump

Filter

CONVENTIONAL PLATFORM MOUNTED WATER INJECTION SYSTEM

CHEMICALSDE AERATOR

•expesive Topside Water Injection System including pump with filter, de-aerator, piping,

l ill

COARSE FILTER

BACKFLUSH /SAND FILTER

DE-AERATOR

BOOSTER PUMP

WATERINJECTIONPUMP

valves, etc. will generate

• extra Interface Engineering

i l f difi i / i

PIPE

PLATFORM

•expesive Platform modifications/extensions

•expesive Platform installation, hook-up and commissioning work

PLATFORM•extra space & Weight requirement

•expesive high pressure water injection i liLIFT PUMP pipeline

PIPE TO WI WELLPIPE

SUBSEA RAW SEAWATER INJECTION SYSTEM

SUBSEA RAW SEAWATER INJECTION SYSTEM

TOPSIDE CONTROL SYSTEM

PLATFORMPLATFORM

bili lumbilical

PIPE TO WI WELLFILTER

CHEMICALS

WATER INJECTION PUMP

PIPE

DUMP VALVE

Columba E Location

Water Injection Objectives

• Provide WI support to E-2 and E-5 producers • Add reserves and accelerate production

E4E1Z E2 E5E2

E3YE5

E6 E7

ODT 12473ft TVDSSODT 12473ft TVDSS

Subsea Water Injection System

Topside – Ninian S. Platform•Power & Control module on the host platform• New chemical injection package

Fib ti b d t ti• Fibre optics based automationand control system

•Subsea• 8km Power and Control umbilical

S b F D l t ti• Subsea Framo Dual pump station• 2 x W.I. pumps• 2 x 100% filter unties2 x 100% filter unties• 1 x subsea control module

• 2 x 6” flexible flowlines to XT’s• 4 x controls jumpers• 2 x 10k subsea XT’s

Process Diagram

Filter backwashFilter A

80 microns

Filter backwash

Inlet strainerFilter B

Wi pump 1 Wi Pump 2

M M

Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass

y , y ( )

Max flowrate 63,000 bbl/day at 222 bargMin flowrate 18,000 bbl/day at 390 barg

FDS in Protection Structure

Protection structure: L x W x H = 23m x 10 x 6.5

Weight = 110 T

Pump Module: L x W x H = 8m x 7 x 5.5

Weight = 100 T

FDS In Protection Structure

FDS Components

WI Pumps By-pass Valve Insert

Filter Units Control Pod

8 x 6 x 7m8 x 6 x 7mCirca 110te.

Process Diagram

Filter backwashFilter A

2 x 100% FiltersFilter backwash

Inlet strainerFilter B

Wi pump 1 Wi Pump 2

M M

Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass

y , y ( )

Filter

filtrationfiltration

backwashbackwash

Subsea Water Injection System

•Subsea•Subsea Framo Dual pumpSubsea Framo Dual pump station

• 2 x W.I. pumps• 2 x 100% filter unts• 1 x subsea control module

Process Diagram

Filter backwashFilter A

Filter backwash

Inlet strainerFilter B

Wi pump 1 Wi Pump 2

M M

Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass

y , y ( )

Norsk Hydro - Troll Project First Subsea Water Injection Pump (Produced Water)

Framo Engineering have generatedFramo Engineering have generated more than 800,000 hrs

of Operating experience for subsea pumps

Subsea Retrievable Water Injection Pump

• Motor rating 2.3 MW

• Design Speed 3600 rpmDesign Speed 3600 rpm

• Design Capacity 360m3/h @ 3600 rpm

• Rated dP typical 160 bar

• Design pressure 400 bar

• Height 5 m

W i ht 20 T• Weight 20 T

• Oil submerged electric motor

• Centrifugal pump designg p p g

• No dynamic seals to environment

• Retrivable from light intervention vessel

Subsea Water Injection System

•Subsea•Subsea Framo Dual pumpSubsea Framo Dual pump station

• 2 x W.I. pumps• 2 x 100% filter unts• 1 x subsea control module

Subsea Pump Control System SEM Configuration

SEM ConfigurationSEM Configuration• Up to 36 process sensors• Up to 30 solenoid valves• Up to 12 Serial interfaces• Up to 12 Serial interfaces• 600 Watt for external power supply• Configuration is flexible due to open architecture

Key Specifications• Bandwidth Fiber Optic: 100 Mb / 10 Mb• Redundant communication paths• Redundant communication paths• Electromagnetic noise immunity• Power consumption: 100 Watt • Temperature 0 to 50 °C (-20 to 50 °C storage)Temperature 0 to 50 C (-20 to 50 C storage)• Water depth down to 3000 meters

Designed and built to:Designed and built to:• ISO 13628 Part 6

Installation / Stack-up Test

Umbilical

8km Power and Controls8km Power and Controls umbilical

Power & Control Umbilical8km

Umbilical Installation

Umbilical loaded out -Rosyth

Platform termination pulledin – Ninian South

S b T i tiSubsea Termination Unit deployment

Topside Power & Control Module

Topside – Ninian S. Platform•New 90 tonne power & controlNew 90 tonne power & control module on the host platform• New chemical injection package• Fibre optics based automationand control systemand control system

Topside Power & Control module installed on Ninian South

split in 3 parts

PCM Installed topside on Ninian S

System Integration Testing

Topside – Ninian S. Platform•New 90 tonne power & control pmodule on the host platform• New chemical injection package

Fib ti b d t ti• Fibre optics based automationand control system

•Subsea• 8km Power and Controls umbilical• Subsea Framo Dual pump station

2 W I• 2 x W.I. pumps• 2 x 100% filter unties• 1 x subsea control module

• 2 x 6” flexible flowlines to XT’s• 4 x controls jumpers• 2 x 10k subsea XT’s

Columba E – First Raw Seawater Injection System

• PROTECTIVE STRUCTURE & FRAMO DUAL PUMP STATION INSTALLED MAY 2006

• PUMPS DELIVERED JUNE 2007

START UP JULY 2007• START-UP JULY 2007

Framo Dual Pump Station PROTECTIONStation PROTECTION

STRUCTURE

Project Qualification & System Testing

Corresponding tunnel

Subsea Test Dock

Deep Water Quay

System Integration (SIT) – Dry Dock

System Integration (SIT) – Wet Dock

Structures Installation

Structure Loadout Barge - Norway

Pump station Deployment

Protection Structure Deployment

Project Schedule – Sanction to Start-up

• Sanction Feb ’05

• Pump station & umbilical installed May ‘06

• Topsides PCM Installed Oct ‘06 p

• Drilling commencement Nov ’06

T id S t P i i i C l t M ‘07• Topsides System Pre-commissioning Complete Mar ‘07

• Drill & Complete WI Wells May ‘07

• Subsea Hook-up end May ’07

• Subsea & Full System Commissioning Jun ‘07

• Water Injection start up Jul ‘07• Water Injection start-up Jul 07

FRIEND® (FRamo Interactive Enabling Diagnostics)

Internet Service Provider

FE Sandsli

Subsea St tiStation

Online connection between Framo Control Room and Customer SiteCondition monitoring through Real-time streaming of Quality DataInteractive Engineering Applications availableCommunication Functionality Documents & Status ReportsCommunication Functionality, Documents & Status Reports

All made available through dedicated Client FRIEND® Web Portal

Summary - Conclusions

• RSWI a viable solution• increase in injection capacity• minimised impact on existing facilities• re-deployment possible?

• Robust proven technology – a new applicationRobust proven technology a new application• reliable – 100% uptime since start up one year ago• in depth qualification of “new” elements

Summary - Conclusions

• Take the opportunity of high specification• e.g. single controls system• supports economic viability• simpler, efficient interface

• Mitigating project risksMitigating project risks• key elements with a single “system provider”• additional extensive testing performed filter and SCM• comprehensive SIT, wet & dry test (Framo Subsea test

d k) d h diff ”T ti b d thdock); made a huge difference. ”Testing beyond the normal; built operational confidence”

Summary & Conclusions

• Operations from the beginning• Intervention designed in….• Operations involvement with comprehensive training• Life time support: FRIEND

• RelationshipsRelationships• CNR and Framo worked closely to resolve challenges