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Slide 1/31
The Subsea Sand Management Challenge: “What to do with the sand?”
Hank Rawlins, PhD, [email protected]
Slide 2/31
Purpose & OutcomePurpose
• Identify drivers for subsea facilities sand management• Provide a focal point for discussion on subsea processing
with focus on “What to do with the sand?• Identify and analyze conventional, unconventional, and
unique options to reveal technology gapsOutcome
• Approaches include neutralizing effects, improving conventional design, and separation with disposal
• Investigate technology analogues from other industries• Improve hydrocarbon recovery through inclusionary
production (SPE 164645)
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 3/31
12 Years of ProgressTop 5 Technology Needs
1. Seabed separation & disposal2. Integrated subsurface/surface3. Sand cleaning4. More case studies/examples5. Instrumentation
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 4/31
Produced Solids (Sand)Inorganic, Insoluble, Particulate Material
• Not asphaltene, paraffin, wax, hydrate, or resin (organic)• Not precipitates or scale (soluble or non-particulate)• Sand - ISO 14688-1:2002 / ASTM D2487-83 (63-1700 µm)• Solid particles that are separable in facilities equipment
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
1 mm
Corrosion
Quartz Sand
Onshore Field, Austria
Sand
Clay
WaterOil
Deepwater South China SeaOTC Asia 24705-MS
Slide 5/31
Natural Vs. Artificial SolidsNatural Solids
• Indigenous reservoir material• High angularity, 25-150 μm
median size, ~2650 kg/m³• Low, steady-state, continuous
production• Failure mode – high
concentration burst production
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Artificial Solids• From external intervention• Frac sand, proppant, drill mud, cement fines, corrosion
product, gravel pack, injection fines, etc.• Higher s.g., rounder shape factor, larger avg. particle size• Often handled as planned event
Sand and coal from Brent Delta 1996
Slide 6/31
Motivation for Sand HandlingErosion
• Pipe components and valvesFilling
• Vessels, tanks, and low velocity zonesInterference
• Instruments/valves (plugging or range of motion)Oil-in-Water Content
• May not be critical for subsea
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Erosion
Filling Plugging
OIW
Slide 7/31
Sand Management PathsA. Conventional Approach
• Manage solids production or system configuration using established rules or technology
B. Solids Treatment• Modify the solids, in-situ, to reduce or eliminate their
deleterious effectsC. Solids Removal/Disposal
• Separate solids from the well fluids and manage as separate flow stream
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 8/31
Sand Management Paths
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Downhole mechanical intervention
Reduce production below solids level
Reduce pipe velocity
CONVENTIONAL
Erosion resistance materials
Manage erosion
Design
Pass through solids
Agglomerate
Partial/full dissolve
Chemicals
Modify shape
TREAT SOLIDSCoat particles
Core laminar flow
Modify flow path
Pipe in pipe design
Desander Cyclone
Filters
Gravity
Inertia / Viscous trap
Inject into disposal well
Mechanical
Clean & Seafloor discharge
Chemical
REMOVE SOLIDS
Compress to puck
Dispose
Repackage Containerize
Adhesive / cement
Grinding attrition
Ultrasonics
Disintegrate
Electrical discharge
Solids ManagementChemical dissolution
Dedicated pipeline
New flow stream Contain / Pig line
Float to surface
Wellstream
Downhole
Slide 9/31
Technology Gaps
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Reliable, known technology Required to meet subsea demands
http://www.scanadu.com/
Slide 10/31
A. CONVENTIONAL APPROACH
Manage solids production or system configuration using established rules or technology
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 11/31
Exclusion or Flow/Material DesignExclusionary Production
• Well completion equipment• Reduce educe well output below sand production level
Flow Design• Lower velocity in piping to minimize erosion• Increase velocity to prevent solids from settling
Material Design• Design components with manageable erosion or increase
MOC for longer erosive life (material type or thickness)Separate sand ahead of subsea system and reintroduce downstream
• Put solids back into production stream• Put solids into disposed stream (i.e. water injection)
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 12/31
B. SOLIDS TREATMENT
Modify the solids, in-situ, to reduce or eliminate their deleterious effects
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 13/31
Effect of Sand Morphology on Erosion
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
A.K. Cousens, Fitzwilliam College, "The Erosion of Ductile Metals by Solid Particle Impact", February 1984, PhD Dissertation
B.S. McLaury and S.A. Shirazi, SPE 56812, Generalization of API RP 14E for Erosive Service in Multiphase Production, 1999.
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Mas
s Lo
ss (m
g)
Mass of Erodent (g)
Spherical Glass
Crushed Glass
Erosion of mild steel with glass particles (95-105 µm) at 50 m/s in air
Slide 14/31
Effect of Particle Size on Erosion
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Zhang, Y., Reuterfors, E.P., McLaury, B.S., Shirazi, S.A., Rybicki, E.F., “Comparison of computed and measured particle velocities and erosion in water and air flows,” Wear 263 (2007), 330-338.
McLaury, B.S., Wang, J., Shirazi, S.A., Shadley, J.R., Rybicki, E.F., “Solid particle erosion in long radius elbows and straight pipes,” Paper 38842 presented at the SPE Annual Technical Conference and Exhibition, San Antonio, TX, 5-8 Oct, 1997.
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Pene
tration Ra
te
Erosion Ra
tio (m
ass of partic
le/m
ass loss of target)
Particle Size (micron)
Erosion Ratio
Penetration Rate
1.0 10 E
′ ′
~ 326
.
ER=erosion ratio (mass of particle/mass loss of target)
~ ~.
h=penetration rate (m/s)
Rapid decline
Threshold particle size:20 microns methane and 100 microns water
Slide 15/31
Particle Coating
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
http://www.ussilica.com/products/proppants
http://www.carboceramics.com/carbobondrcs/
Coat the particles and reintroduce into production streamReduce edge sharpness and increase sphericity (0.7-0.9)Make particle soft/resilient to impactReduce net density (impact reduction and easier to carry)Tech transfer from proppant productionCoating materials: phenolic, polyurethane, epoxy, waxInorganic coatings (patent): SbO3, Bi, B2O3, CaBaF, Cu,
Graphite, In, PbO, PbS, MoS2, ZnO
Coating Method (TBD): powder, liquid, reaction, precipitation
Slide 16/31
Partial/Full Chemical DissolutionDissolve to reduced particle shape or sizeInorganic AcidNaOH
6 → 2
2 →
Organic acids (citrate, oxalate, and pyruvate) increase dissolution rate 8-10X compared with water(Bennett, P.C., Melcer, M.E., Siegel, D.I., and Hassett, J.P., The dissolution of quartz in dilute aqueous solutions of organic acids at 25°C, Geochimica et Cosmochimica Acta, Vol. 52, Issue 6, June 1988, 1521-1530)
Increasing temperature, and pressure both increase solubility of silica(Mroczek, E., and Christenson, B., Solubility of quartz in hypersaline brine – implications for fracture permeability at the bittle-ductile transition, Proceedings of the World Geothermal Congress 2000, Kyusho-Tohoku, Japan, May 28-June 10, 2000)
Increasing BET surface area or dislocation density both increase dissolution rate (i.e. grind w/ dissolution – sharp edged have higher chemical potential) (Blum, A.E., Yund, R.A., Lasaga, A.C., The effect of dislocation density o the dissolution rate of quartz, Geochimica et Cosmochimica Acta, Vol. 54, Issue 2, Feb 1990, 283-297 and Gautier, J-M., Oelkers, E.H., and Schott, J., Are quartz dissolution rates proportional to B.E.T. surface areas?, Geochimica et Cosmochimica Acta, Vol. 65, Issue 7, April 2001, 1059-1070)
Increasing cation concentration increases dissolution rate of quartz (Ba2+>Na+~Ca2+>Mg2+ where Ba2+ provides 114X rate compared to DI water)(Dove, P.M., The dissolution kinetics of quartz in aqueous mixed cation solutions, Geochimica et Cosmochimica Acta, Vol. 63, Issue 22, 1999, 3715-3727)
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 17/31
C. SOLIDS REMOVAL/DISPOSAL
Separate solids from the well fluids and manage as separate flow stream
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 18/31
Sand Separation TechnologiesScreen/FilterCyclonic
• Desander, Inline, AugerRotordynamicGravity SettlingPipe Trap
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
http://www.fmctechnologies.com/en/SeparationSystems/Solutions/SolidsHandling.aspx
Paper SPE 166118 Design of a Cyclonic Solids Jetting Device and Slurry Transport System for Production Systems
Subsea Wellhead Desander
Slide 19/31
Particle ComminutionGrind sand to particle size below critical limit or to modify morphology
• Ultra-fine grinding, attrition mill, vibratory tumbler• Employ methods from mining, ceramic, paint, paper,
pharmaceutical, or other fine particle industriesMechanical comminution
• Ring & puck mill, disc pulverizer, oscillating mill, micro-powder mill, high-press grinding mill
Media methods• Planetary, vibratory, or stirred mill
Non-moving parts methods• Jet mill, ultrasonic wet-milling, electric pulse discharge
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 20/31
Comminution Equipment
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Metso Stirred Media Detritor
Hielscher ultrasonic processor
Sturtevant Micronizer® Jet Mill
Ring & Puck Mill Disc Pulverizer
Slide 21/31
Particle ConsolidationConsolidate particles into solid or semi-solid shape, for ease of carrying or “contained” seafloor disposal
• Compress into puck (mechanical densification)• Add adhesive polymer an extrude• Add cement to make brick
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge6th ESMF · March 26-27, 2014
http://www.mechanicalengineeringblog.com/tag/cement-extrusion/
Carver® Hydraulic Press
Slide 22/31
ContainerizeCollect into…
• bag/tube/flexible-container• pig and send up pipeline• vessel/bin and retrieve by ROV or wireline• vessel/bin and float to surface
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge6th ESMF · March 26-27, 2014
http://freeassociationdesign.wordpress.com/2012/01/24/21st-century-sand-bags/
http://www.subsalve.com/ http://en.wikipedia.org/wiki/Pigging
Sand bagging and lifting equipment Paper OTC Asia 24705-MS
Slide 23/31
Sand CleaningMechanical (agitation)
• Recirculation loop with cyclones, slop oil slurry cleaning, beach sand cleaning
Chemical• Dispersant, biological, detergent
Thermal
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge6th ESMF · March 26-27, 2014
http://www.medscape.com/viewarticle/726761
Sand cleaning system for BP Venezuela 1997
Inlet and sand/water outlet from cleaning loop along with analysis method
Slide 24/31
Slurry Fracture Injection
Solids injection into disposal reservoir• Used significantly for drill cuttings• OnePetro papers and SPE Monograph• Typically batch process http
://ww
w.id
s-environm
ent.com/C
omm
on/Pap
er/Pap
er_123/An%
20Introd
uction%20to%
20Slurry%20Injection%
20Technology.htm
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Deoiler/desander system with solids disposal via slurry fracture injection for Chevron on Barrow Island (2008)
Slide 25/31
INSTALLED SYSTEMS SUMMARY AND RECOMMENDATIONS
RPSEA Report 09121-3100-01, 24-Apr-12, RPSEA Ultra Deep Water Disposal of Produced Water &/or Solids at the Seabed
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 26/31
RPSEA ReportRated solids handling for subsea at TRL 3
• Used 100 ppm inlet design at 700 lbs/dayDisposal requirements
• Selected locations at 1 wt.% oil on dry solids• U.S. does not allow solids discharge• Water injection quality at <5 ppmv and < 2 microns
Recommendations• Put sand into retrievable containers (7.8.3)• Add back to oil stream (7.10.2)• Manage through velocity
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 27/31
RPSEA: Installed Systems SummaryPetrobras Marimba, Congro, Malhado, Corvina, Canapu and Shell BC-10, Perdido
• G/L, sand flows with liquid to surfaceTotal Pazflor
• G/L, sand flows with liquids, backup sand flushing arrangement
Statoil Troll C• Sand flows with injection water
Statoil Tordis• Sand jetting to desander to injection well (after pump), but
changed to flowing to surfacePetrobras Marlim
• Sand removed pre-separator, sand jetting, produced water desander, sand put back into oil line
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge
Slide 28/31
ConclusionsSubsea Processing Requires Sand Management
• All wells produce sandNo New Equipment Required for Separation
• Proven equipment available topsides• Packaging for deepwater use needed
Solids Handling Main Concern• Erosion, filing, interference, or oil-in-water• Neutralize, improve conventional design, separate/disposal• Primarily manage through velocity• Separation with injection: flow-line, w/water, or discrete reservoir• Containerize a viable option
Closing Technology Gaps• Coordination between major stakeholders• Cooperative development approach• Qualified experienced innovative partners
6th ESMF · March 26-27, 2014 H. Rawlins – The Subsea Sand Management Challenge