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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