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3 rd Generation Online Desander 2012 Sand Management and Control Workshop Stork Desanding Presentation 27/2/12 – 1/3/12

2012 Sand Management & Control - Desanding Presentation

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2012 Sand Management & Control - Desanding Presentation

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3rd Generation Online Desander

2012 Sand Management and Control Workshop

Stork Desanding Presentation

27/2/12 – 1/3/12

Colin Sherwood – 3rd Generation Online Desander – 16th February 20122

Presentation Agenda

• Stork’s Commitment to Improving HS&E Performance

• Specialist Cleaning / Desanding Function within Stork

• The Stork Sand Removal Solution

• Concept

• Safety Features and Supporting Safety Reviews

• System Capability

• Frequently Asked Questions

• Working with Clients

• First Step

• Testimonials

• Contacts

Colin Sherwood – 3rd Generation Online Desander – 16th February 20123

Stork Commitment to HS&E

Launched within RBG in 2009, the objective of the ‘REACH’ initiative is to create

a stronger, safer culture throughout the organisation.

Following the acquisition of RBG by Stork Technical Services in 2011, STS are

adopting ‘REACH’ across the company.

After the first complete year in operation ‘REACH’ has delivered:

• 51.2% reduction in lost time incident frequency (LTIF) in the UKCS

• 38.4% reduction in LTIF globally

• The actual potential and severity of incidents is decreasing

• An improved HSEQ culture overall

teamwork – involvement – encouragement – reward – communicationmonthly campaigns – formal reports – recognition awards – library of resources

attitude to safety

Colin Sherwood – 3rd Generation Online Desander – 16th February 20124

Operations Support, Specialist Cleaning

Desanding function within Stork organisation

Access Systems

Electrical & HVACR

Inspection & NDT Services

Rig Repair

& Upgrade

Mechanical Services

Specialist

Cleaning

Online Desanding

Stork UKOperations

StorkInternationalOperations

OtherStork

Services

OperationsSupport

Colin Sherwood – 3rd Generation Online Desander – 16th February 20125

The Stork Sand Removal Solution - Concept

To fluidise the sand and remove the sand slurry …

… without causing undue process disturbance.

Non Intrusive “Solids Extraction” Arrangement

RecycledProduced

Waterfor Jetting

FluidisedSandfrom

Separator

Colin Sherwood – 3rd Generation Online Desander – 16th February 20126

The Stork Sand Removal Solution – Concept

Key Features

SolidsSeparationPackage

Package sockets supply:• Solids Wash Tank• Recovered Liquid Tank• Filter Unit• Gas Detectors• Level Switches

Single 440v supply to package

Solids Wash Tank

Solids SeparationPackage fitted with long sling set

ISO BLOCK LOCK

All access is builtwithin the unitframes

Colin Sherwood – 3rd Generation Online Desander – 16th February 20127

The Stork Sand Removal Solution

Delivery Objective

To perform separator desanding operations:

• Without safety incident,

• Without environmental incident,

• Without loss of production,

• As a cost effective sand removal solution.

With the additional benefit of:

• Reduced personnel exposure to process

associated hazards by elimination of vessel

entry works.

Colin Sherwood – 3rd Generation Online Desander – 16th February 20128

The Stork Sand Removal Solution – Asset Performance Benefits

By performing Online Desanding the Asset can:

• Maintain performance by elimination of unplanned outages due to:

• Sand affected instrumentation,

• The need to manually remove sand in order to restore separator

performance, or

• Optimise S/D duration by:

• Removal of majority of sand ahead of the S/D, not as part of the S/D

• Reduce sand carry over leading to improved reliability of downstream

equipment,

• Optimise bed space utilisation by using a small crew for a short duration

• Minimise risk of safety & environmental impact by using:

• Purpose designed equipment,

• Equipment specific trained crew

Colin Sherwood – 3rd Generation Online Desander – 16th February 20129

The Stork Sand Removal Solution – Asset Performance Benefits

Asset performance impact:

Consider an asset producing 20,000 bbls/day

Separator is loosing performance,

• Overboard water spec is deteriorating,

• Level control instrumentation problems,

• Sand carrying over to downstream equipment …

Traditional solution:

• Take a +/- 10 day S/D to manually remove sand,

• = +/- $23,600,000* in lost revenue

*Brent crude at $118 per barrel on 17/2/12

Colin Sherwood – 3rd Generation Online Desander – 16th February 201210

The Stork Sand Removal Solution – Asset Performance Benefits

Stork’s alternative solution:

Perform ‘online’ desanding of separator,

• NO deferred oil,

• NO lost revenue,

• Typical desanding job at £160,000 or $244,800

A value for money, innovative solution maximising Asset Performance …

Colin Sherwood – 3rd Generation Online Desander – 16th February 201211

The Stork Sand Removal Solution – Options

Use of Stork Solids Extraction Package

Hose within a hose

Air SupplyAir Supply

FilterPackage

ShearValve

Air Supply

Manifold

Client Separator

FCV

Hose within a hose

Hydraulic Ram &Power Pack

AirSupply

High FlowJetting Unit

Air Supply

SolidsSeparationPackage

SolidsWashTank

RecoveredLiquidTank

RecoveredOil to drains

Sand toDisposal Route

Ventilation to‘safe’ location

FilterPackage

Colin Sherwood – 3rd Generation Online Desander – 16th February 201212

The Stork Sand Removal Solution – Options

Use of Internal Sand Jet Header

X-over

High FlowJetting

Unit

AirSupply

+110v

Dead Man Handle

Ventilation to ‘Safe’ Area

Oil to Drains

Sand to DCB’sor overboard

Water to drains

SolidsWashTank

Filter

PumpFilter

RecoveredLiquidTank

SeparationSkid

FCV

PSV Set attba bar

AirSupply

+440v

Separator

AirSupply

PressureTest /Flush Line

Colin Sherwood – 3rd Generation Online Desander – 16th February 201213

Safety Features and Supporting Safety Reviews

Safety – by equipment design

All desanding equipment is ATEX compliant for operation in Zone 2 hazardous areas.

Desanding skid incorporates a safety / shut down system protecting Stork unit from:

• high pressure,

• tank high level,

• hydrocarbon gas design deviation, and

• H2S design deviation

Emergency isolation valves at the separator outlet and Stork skid inlet.

Jetting hose shear and isolation capability in event of jetting hose becoming

stuck while desanding … it has not happened to date.

Minimal ‘hook up’ requirements – all access platforms, hand rails and ‘hop

ups’ are incorporated in the design

Colin Sherwood – 3rd Generation Online Desander – 16th February 201214

Safety Features and Supporting Safety Reviews

Safety - by Client review

• Independently facilitated design HAZOP involving Stork, Client and independent engineers,

• Comprehensive project specific HAZOP by ConocoPhillips for the Judy Platform

• Pre mobilisation Safety Review by Centrica / Wood Group for Hummingbird FPSO

• Pre mobilisation Safety Review by Centrica / Petrofac for the Kittiwake Platform

• Project HAZOP by Shell for Anasuria FPSO

• Comprehensive project specific HAZOP for BP Caspian

Crew selection – Equipment specific 5 day training course

Colin Sherwood – 3rd Generation Online Desander – 16th February 201215

Capability

Environmental Performance by design

Desanding equipment spread incorporates Stork’s proven ‘Sand Wash’ System

• The Solids Wash Tank has been designed specifically for sand washing to achieve

under 1% Oil on Sand,

• Hydrocarbon based solvent RBG-S001 has been blended for optimal performance

when used in conjunction with the Sand Wash Tank,

• Sand Wash Tank is mounted on weigh cells allowing accurate reporting.

Alternatively, we can discharge ‘dirty’ sand into Drill Cuttings Bins for client

disposal (Onshore)

Colin Sherwood – 3rd Generation Online Desander – 16th February 201216

Capability

Equipment performance by design

• Up to 40 bar1 and 90oC separator conditions

• Solids separation effective for particle size distribution between 50 and 300 microns2

• 10 tonnes/day3 removal when sand washing

• 20 tonnes/day4 removal without sand washing –sand discharge to Drill Cuttings Bins

• Effective jetting radius within the separator is just over 1m

A number of system improvements are being developed for 2012 implementation.

1 A 60 bar unit can be achieved by upgrading of a 40 bar unit.2 A ‘fines’ separation unit is under development – down to 15 micron. 3, 4 Subject to separator arrangement and conditions.

Colin Sherwood – 3rd Generation Online Desander – 16th February 201217

Capability

Stork utilise Thermographic Imaging to monitor sand build up and removal:

• Prior to mobilisation

• During the desanding process to optimise sand removal, and

• Post desanding to provide verification to client of sand removal

Camera image of vessel

Image from thermographic camera showing pre desanding

sand deposits

Image from thermographic camera

post desanding

Colin Sherwood – 3rd Generation Online Desander – 16th February 201218

Capability

Utility requirements:

• Solids Extraction System - Hydraulic Power

Pack

• 440v for 3.5m package

• 110v and air supply for 2.5m package

• Solids Separation Package

• 440v 63a welding socket

• Other units are fed from this skid, always

within 63a socket capacity

• Pump impellors sized to suit 50 or 60 Hz

generation

• Sea Water or Potable Water for initial fill

• Plant air for air movers and diaphragm pumps

• Compressor availability

Colin Sherwood – 3rd Generation Online Desander – 16th February 201219

Capability

Typically, 3 or 4 containers.3.12.442.44Hoses, Consumables

X-overs, valves, fittings, etc3.12.442.44Support Container

2,0002.41.52.4Filter Package

2,0002.41.52.4Pump / Filter Package

Dry wt4,7502.482.482.9Recovered Liquid Tank

Dry wt4,7502.482.482.9Solids Wash Tank

4,5002.482.482.9Solids Separation

Not required on all jobs600

1650

0.5

1.5

0.5

1.1

2.5

3.5Solids Extraction

c/w High Flow Pump Build7,5002.832.453.0Jetting Unit

CommentWeight

(Kg)

H

(m)

W

(m)

L

(m)

Package

(about 10 lifts)

Colin Sherwood – 3rd Generation Online Desander – 16th February 201220

Frequently Asked Question’s

What onshore support is available ?

Operations support:

• In house design supported by

independent engineering

consultancies for design

verification.

Operations Manager

• Desanding Technical Focal Point,

dedicated to desanding operations

Project Manager

• Dedicated to desanding

operations, interfaces with Stork

Measurement Solutions group for

Sand Management Solutions.

What equipment support is available?

Technical Support:

Equipment Support

RPlant – responsible for equipment preparation, inspection, maintenance and certification.

Logistics Support

RPlant – Specialist Shipping Group based in Aberdeen

Colin Sherwood – 3rd Generation Online Desander – 16th February 201221

FAQ’s

Is there risk of erosion when inserting the jetting nozzle into the separator?

Risk put into context:

Desanding pressure – 104 bar* Coating cleaning – 1000 barCoating removal – 2500 barCold Cutting – 2500 bar* Jetting pressure providing optimal quantity of water through nozzle

No cases of separator nozzle erosion have been reported to Stork

Risk mitigation measures:

• Minimise fluid velocities in risk areathrough jetting nozzle design

• Jetting nozzle designs• JU speed manipulation

• Pass through the risk area as quicklyas possible

ErosionRiskArea

Jetting startposition

Risk potential:

Jet impingement on separator nozzleinternal surface in the presence of sand

Colin Sherwood – 3rd Generation Online Desander – 16th February 201222

FAQ’s

We have a ‘No Double Stacking’ policy. How do you propose to work with this restraint?

Stork:

• Have had an independent stability study carried

out,

• Use proprietary ‘ISO Block Locks’ to secure the

units together,

• Use a bumper bar on the lower unit to guide the

upper unit into position,

• Use a long sling set fitted to the upper unit

allowing disconnection from the crane from deck

level.

Stork have in place:

• Lifting Operation Plan

• Lifting Operation Plan Risk Assessment

Colin Sherwood – 3rd Generation Online Desander – 16th February 201223

FAQ’s

How many beds required, durations, equipment weights and footprints?

59 tonnes30 m210Stork

Mk3 Desander

Equipment

Weight

Equipment

Footprint

Lifts from Boat

Stork desanding crew require 5 beds – dayshift working.

Stork estimated desanding duration – 7-8 offshore days.

Colin Sherwood – 3rd Generation Online Desander – 16th February 201224

FAQ’s

What is Stork’s track record in desanding?

Sand (Tones)

Year

2002

142

2003

203

2004

37

2005

60

2006

20 20

2007

12

47

2008

627

1st generation – now ‘retired’

AOD – introduced in 2006 – now ‘retired’

3rd generation – introduced in 2009 – 40 bar and 60 bar units

36

20102009

20

2012

To date

2011

24 028

Colin Sherwood – 3rd Generation Online Desander – 16th February 201225

Working with Clients

While Stork offers a solution for sand accumulation problems we recognise that “one size doesn’t fit all”.

Stork welcomes the opportunity to work with Clients to jointly develop suitablesolutions to sand issues.

Stork can offer:

• Online Desanding tailored to Client requirements

• A wider Sand Management Service involving Stork’s ‘Monitoring Solutions’ group.

• Enhancements for manually removing solids accumulations such as a Vacuum Unit for rapid solids removal

Colin Sherwood – 3rd Generation Online Desander – 16th February 201226

First Step - Capability Assessment

An initial assessment of Stork desanding capability can be carried out based on:

• The Separator P&ID, and• The Separator General Arrangement

Drawing

This first pass assessment determines whether we cannot perform desanding.

Colin Sherwood – 3rd Generation Online Desander – 16th February 201227

Some testimonials …

“I would like to congratulate RBG for the very good work performed on the DALIA FPSO during their

three 2008 missions. Your various interventions onboard for the large desanding campaign have been a

great success.”

Denis Lemarchal, Project Director for TOTAL (2008)

“The crew were professional at all times with real focus on safety and a great work ethic”

“What is obvious is that we have proved the effectiveness of your kit”

Shell Anasuria Operations Supervisor (March 2011)

“In my opinion your guys are the model of professionalism, your set up and equipment fantastic, and the

job has progressed as well as any OIM would want.”

Frank Cairney, OIM Greater Kittiwake Area (March 2010)

“… I have to commend the team for their professional attitude and their understanding of the urgency of

the turn around of the vessel. Their attitude towards maintaining safety standards was impeccable.

The Team Leader was an excellent interface, it ensured I had a comfortable level of security going into

this operation”

Del Petrie, OSP Apache Forties Delta (November 2011)

Thank You

[email protected]: +44 (0) 1224 302260

[email protected]: +44 (0) 1224 302664

Switchboard Tel: +44 (0) 1224 722888

www.storktechnicalservices.com