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Month Day, YEAR
Sand Challenges
Nov, 2019
James Banister
Sand and Solids PLM (Global Technology Manager)
Applications and Process Engineering Manager
Montrose (UK)
james.banister@nov.com
NOV Wellstream Processing
Introduction
Who we are.
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 3
NOV Wellstream Processing
Wide technology portfolio
©2019 NOV | Proprietary and confidential. Process and Flow Technologies |
NOV Wellstream Processing
Deep fluids expertise
Fundamental
analysis of fluids
behaviour
Fundamental
chemistry
analysis
Modelling
of flow pattern &
depositions
Performance monitoring
& fluids characterisation
at site
Performance
evaluations &
optimisations
We think fluids behaviour − not just hardwareWe understand the interactions
between technologies
TEG - Johan Sverdrup SWT - Catcher MEG - Ichthys
SEP - Vessel Internals PWT & SAND - Mariner CRUDE – Johan Sverdrup
1978Kværner Process
Systems
1979Merpro is
founded
1997First sale of MEG
reclamation
system
1991Tore™
technology is
developed
1994Petrex is
founded
2011NOV acquires
Merpro
2012NOV acquires
Petrex
2014Demerger of
Aker Process
Systems;
renamed Fjords
Processing
2015NOV acquires
ProFab
fabrication yard
2016NOV acquires
Fjords Processing
Wellstream
Processing is
formed
2013APS acquires Opus
Maxim including
Flotta facililty
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 6
Separation Processes
• Where solids impact
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 7
Separation ProcessAnd impact of solids
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 8
Separation Process
Chokes
Maximise production
But monitor solids to:-
-limit/prevent erosion
- keep within limitations of
downstream
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 9
Separation Process
Separators
Gradually fill with 150+
micron sand.
Slugging/upsets can lead to
sand surge downstream.
Loss of separation
performance.
- Filling
- Stabilisation of emulsions
De-pressurisation changes
acidity – can lead to fouling
(naphthenates)
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 10
Separation Process
Deoiling Hydrocyclone
Erosion
Blocking
Separation dependent on
viscosity
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 11
Separation ProcessDegasser
80+ micron solids
Gradual filling
Can impact OIW
Co-mingling of water streams
leading to scaling
Reservoir
Pore size?
Injectivity
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 12
Case Study A
• Condensate Field
• Late life
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A Condensate Flow Scheme
A Wells
B Wells
C Wells
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 14
A Condensate Flow Scheme
Blocking with SolidsSolids stabilised emulsion
High WIO
Blocking with Solids
Not used
Slugging
problems
A Wells
B Wells
C Wells
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 15
A Condensate Flow Scheme
A Wells
B Wells
C Wells
Check for chemical impacts
Surface active additives
Avoid over-dosing
Early Solids Removal
Provide residence time for solids drop-
out from water layer
- weirs and levels
- keep solids out of oil
Minimise Shear of oil/water/solids mix
Convert 2-phase to 4-phase separation
Remove/replace clogging and blocking
internals
Remove cartridge filters
Plus measures to improve OIW…
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 16
A Condensate Flow Scheme
A Wells
B Wells
C Wells
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 17
ToreOVD(Tore Online Vessel Desanding)
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 18
A Condensate Flow Scheme
A Wells
B Wells
C Wells
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 19
CYCLONE SIZE SELECTED ON SAND CONCENTRATION, PARTICLE SIZE AND REQUIRED EFFICIENCY
• Cyclonic action separates the sand from the produced water
• Ceramic liners remove sand down to 15 micron
• Sand is removed from the vessel while still on-line
• Solids transferred to a ToreScrub, Sand bagging frame, mud skip or similar
ToreTrap
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 20
A Condensate Flow Scheme
A Wells
B Wells
C Wells
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 21
ToreScrubCleaning sand for discharge
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 22
TorescrubCleaning the sand
One page technology description + picture• XXX
Diluted Slurry
Oily water
Feed waterSolids are re-circulated with
sand fluidising device
Eductor boosts the
pressure & dilutes
the slurry
before cleaning.
Cyclone scrubs solids & discharges
them to the vessel
Suction
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 23
• Sand Production Prediction is unreliable– Comes with the water
– Completion failures
• 30 micron sand easy to remove, 10 micron sand expensive/difficult to remove
• Produced water solids are fouling– Clog filter cartridges
– Can’t use backwash filters
• Tie-ins, stimulation leading to solids
• Unnecessary Expense?– May not be needed for many years
– Need to be used regularly even when no sand
• Sand dewatering/cementing
• Water consumption
Challenges
©2019 NOV | Proprietary and confidential. Process and Flow Technologies | 24
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 25
Bagging Frames and Containers
• Simple to complex
• Vessels to open bags
• Mud skips
• Builder’s bags
©2017 NOV | Proprietary and confidential. Process and Flow Technologies | 26
Well Head Desanding
ADVANTAGES
• Eliminates Choke Wear and Flow Line
Problems
DISADVANTAGES
• Multi-Phase Flow – Higher Solids Cut Point
• High Pressure Design ($$$)
• One Well : One Desander
• Space and Weight
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