Production Chemistry Networking Event 3 A Holistic Systems ... · Mercaptans, Mercury Desalination, SRP, PWRI, Reuse, Unconventional BS&W, Sulphur, Mercury, Organic chloride Asset

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Production Chemistry Networking Event 3

A Holistic Systems Approach to Production

Chemistry Input to Flow Assurance

Colin Smith – Production Chemistry Technical Authority

E-mail: [email protected]

Tel: +44 (0)1784 417154

Event date: 02/10/2018

Event hosted by Richard Barr, Proserv

What is Production Chemistry?

2 A presentation by Wood. October 2018

Impact Gas Water Liquid

Hydrocarbons

Production HydratesEmulsions, Scale,

Sand/fines

Wax, Asphaltenes,

Naphthenates,

Foaming

Product ValueH2S, CO2, DMS,

Mercaptans, Mercury

Desalination, SRP,

PWRI, Reuse,

Unconventional

BS&W, Sulphur,

Mercury, Organic

chloride

Asset IntegrityH2S, CO2, chemicals,

Corrosion

Chloride, Bacteria,

Sand, Hg, Corrosion

Organic acids,

Organochlorides

Environmental /

HSE

Compliance

Flaring / Emissions

Oil in water, WSOs,

Contaminants,

NORM/LSA Scale

Oil in water

Organic Mercury

Production Chemistry is the management of the chemical properties of fluids that can impact production, product value, asset integrity or

environmental/HSE compliance

Unmitigated Production Chemistry - 1


GAS HYDRATES

NORM SCALE

WAX- PIGGING DEBRIS

ASPHALTENE

FLOCCULATION

B

L

O

C

K

A

G

E

S

Unmitigated Production Chemistry - 2


CALCIUM NAPHTHENATE (CaN)

CORROSION

Production Chemistry Issue - Severity

5 A presentation by Wood.

PC / FA Issue Location of Fouling /

Deposition

Fouling / Deposition to Form Blockage -

Severity

Production Flow Period to See a

Problem

Hydrates Subsea Very High Hours - Days

Halite Downhole/subsea Very High Days

Naphthenates Topsides High 2 – 4 weeks

Asphaltenes Downhole Medium to High Months

Wax Downhole/Subsea Medium to High 4 weeks to 3 months

Scale Downhole /

Subsea / Topsides

Medium to High > 6 months typically (can be < 3 months)

Biofilms / Biofouling

Subsea Medium to Low > 6 months to years

Emulsions All Low Years

Sand (assumed well

completions hinder sand production rate)

Topsides Low Years

Considering worst case scenario – uncontrolled production, ~ 120 Kbopd

New Oil & Gas Field Development Projects


Typically between Appraise-Concept Select-Define phases

Project Team• Project Lead/Manager/Engineer

• Front End Engineer(s)• Process Engineer(s)

• Reservoir Engineer(s)

• Subsea Engineering Specialists

• Corrosion / Materials Engineer

• Production Technology / Petroleum Engineering (Wells)

• Flow Assurance Engineer(s)

• Process Chemist

A collaborative team approach!• No working in isolation

• Constant communication, data sharing / review

• Regular team meetings / workshops / peer reviews

• Joint reports

Project Life Cycle – FA/PC/Process Activities


Exploration

& AppraisalConcept

Select Define Execute Operate

Life of Field Operation

Decommission

Core Analysis &

Geochemistry

Longer Term

Water Injection

Studies. EOR,

Chemical Squeeze

Onsite & Lab Core

Flooding

Formation &

Injection Water

Composition

CO2, H2S, He, RSH, Hg,

Radon, Arsenic,

Vanadium, Calcium

Naphthenate

Contaminants

PC Risks: Scaling,

Asphaltene, Wax

deposition, CaN

PVT Analysis

Implications

Well Test

Sampling SoW

Chemical Injection

Design, Chemical

HSE

BOD

Start-up, Shut-

down Strategies

FEED, Flowline

Design, Field

Layout

Mitigation

Philosophies &

Strategies

Fluid & Material

Compatibilities

Hydrate, Wax,

Corrosion,

Asphaltene, Scale

Deposition

Modelling

Corrosion and

Chemical

Monitoring

Chemical

Management

Onsite Lab Design

Operating and Lab

Procedures

Commissioning

Plan

Wet Lay-up,

Hydrotesting

Chemical

Packages

Chemical Selection

& Qualification

Commissioning

Support

System

Performance

Monitoring &

Evaluation

EOR Options Well

Workover

Process &

Chemical

Optimisation

FDP, WFSs, BfD,

CSR, prelim CRR

Final CRR

Oil assays, oils

blending tests

• Hydrocarbon phases properties & composition

– Oil, gas, condensate, reservoir fluid

• Formation water properties & composition (contamination)

• Gas phase issues

– Corrosion

– Hydrates

– Souring / H2S

• Oil / Condensate phase issues

– Asphaltenes

– Wax (deposition and gelation)

– Corrosion

– Emulsions / rheology / separation / foaming

– Naphthenates & Soaps

– Scaling (incl. NORM, halite, sulphides etc.)

Prod. Chem. Input to Flow Assurance – 1


• Water phase

– Scaling

– Corrosion

– Separation / Emulsions

– Microbiology

– Produced water treatment

– Water Injection / recycle / reuse / disposal

• Contaminants – Across all phases

– Organic acids

– Sulphur species

– Heavy metals, e.g. Mercury

– Arsenic / arsenates

– Organochlorides

• Use of Analogue fields fluid data if have no samples/poor samples

• Understand your fluids – define the issues – A correct basis is a must!

Prod. Chem. Input to Flow Assurance – 2


PC & FA Workflows


FA & PC new oil & gas field developments workflows

• Oversee production fluid characterisation studies

• Collaboration = well defined fluids basis of design (BoD)

• Risk assess for wax, asphaltenes, hydrates, emulsions, foaming,

souring, corrosion, scaling, soaps, contaminants, water

treatment etc.

• Combination of modelling, lab experiment & analysis work

• Define PC/FA problem solutions – design, operational &

chemical solutions

• Oversee the screening & qualification of chemicals &

compatibility

• Compile Chemical Requirements Reports (CRRs)

• Develop mitigation strategies

incl. Chemical Management Strategy (CMS)

Asphaltene Risk Assessment Workflows


PC – FA Work Program - 1


• Develop and set the Production Fluids Basis

- Formation Water composition / properties

- Hydrocarbon oil/condensate properties

- Gas composition

- Contaminants

• Identify any BoD gaps/uncertainties requiring further work (Holds)

- Perform lab testing required to fill any basis data gaps

- Actual or restored samples requirement

- Identify best labs to do fluid properties work, e.g. oil/condensateliquid properties

• agree SoW, generate RFQs, send to labs & review responses

• select best laboratory for work & generate PO

• oversee lab testing & handle any queries,

• Review laboratory testing report

• interpret results for project

- Run simulation modelling as required, e.g. scaling predictions



• Full Production Chemistry risks assessment developed

(including modelling & comparison to analogues, as required)

- Hydrates

- Scale (including halite for FW breakthrough case)

- Corrosion

- Emulsions / separation (soaps)

- Foaming

- Wax,

- Asphaltenes

- Naphthenates

- Contaminants (including Mercury) & meeting export specs

- Produced water treatment aspects

- Microbiology (biofouling risk)

• Full FA risks assessment performed – PC/FA data exchanged

• Rank the PC/FA risks & flag up those needing chemical control



• Define high level chemical requirements to control any identifiedrisks

- Hydrates

- Corrosion

- Scale (+ halite?)

- Emulsions / separation & produced water treatment (PWT)

• Liaise with project disciplines – define system conditions underwhich chemicals will be applied (e.g. P, T, flow regime, shear stressetc.) including if any need for downhole injection – Liaise with FA

• Engage various chemical vendors for their recommended chemicaloptions & their product application ranges / limitations

- Product stability,

- Product performance,

- Environmental aspects

- Product compatibility characteristics

- Input into umbilical core chemical requirements



• Oversee any laboratory qualification testing of recommendedchemicals, define target chemical injection rates, select injectionlocations & interpret test results for project

- Define SoW, RFQs to labs, select a lab, interpret results

• Investigate compatibility of tieback and hub production fluids

• Investigate compatibility of treatment chemicals

- With production fluids

- With selected materials (steels, elastomers)

- With hub production fluids

- With hub treatment chemicals

- Any common chemicals possible?

• Work with other disciplines (e.g. FA, subsea) to design the chemicalinjection facilities (downhole, subsea & topsides, plus umbilical)

• Define number of cores needed, core diameters, chemicaldeliverability etc.



• Field production chemicals regulatory requirements preparationbefore EXECUTE phase

- HSSE,

- Environmental,

- Chemical permitting etc.

• FA Summary report generated

• Ongoing throughout – generate a Chemical Requirements Report,CRR

- A catch all ‘live’ document

• Move into FEED or done during FEED / pre-FEED

Production Chemistry & FA Integration

October 2018

• Representative fluid samplesrequired

• Sample testing providesexperimental data (wax,asphaltenes, hydrates etc.)

• FA modelling provides riskassessments for different scenarios& helps decision making on theoverall concept

• Comparison of lab test data & FAmodels output – tune and validatethe models

• Apply operational experience

• Use analogues knowledge

• Apply lessons learned

• Co-operation is key to yieldingrepresentative results

PC+FA Involvement

PC+FA Involvement

When it goes right! (subsea tieback to existing hub)• Steady state flow covered – mitigations agreed by team

• Transient operations covered (start-up/restart/shutdowns)

– E.g. hydrate management (THIs, KHIs, cocktails)

• Impact of flow regime/slugging/surges/Liquid hold up) – line/riser

• Chemical injection locations agreed by project team

• Chemical injection facilities designed with flexibility (+sparing) for life of field (plus storage requirements, cleanliness etc.)

– Allow for low to high production rates (+ turndown)

– Allow for compositional changes (e.g. inj. water breakthrough)

• CIMVs option considered collectively (team)

• Umbilical core design & chemicals deliverability optimal/flexible

• Chemical compatibility / core flushing / environmental impacts

• Operating philosophies and management strategies developed collectively by various disciplines

Proactive PC – FA Collaboration - Output

October 2018

Wax related properties derived in laboratory (dead / live fluids)

– Used for tuning FA modelling of wax deposition in subsea pipelines

– For different scenarios look at live WAT vs arrival temperatures

– Impact of pressure/gas/water on gel strength / restart pressure

– Drive wax management strategies

– Select insulation/heating/pigging/chemicals etc.

PC – FA Key Collaboration – Wax Example

October 2018

Exploration

Identify & Assess

WAT / WDT

Wax Content

Pour Point (PP)

Viscosity

Appraisal / Development

Identify & Assess / Select

Further WAT / PP tests

HTGC

Yield Stress / Restart

Wax Deposition Rate

Live WAT determination

Development

Select

Chemical Tests

Thermodynamic Modelling

Deposition Modelling

Flow Loops

R&D

Required Optional

Laboratory Testing - Wax


Gelation /

Pipeline Restart

Pour Point

Yield Stress /

Pressure

Deposition

WAT

Viscosity

HTGC

Analysis

Wax Diffusion

Coefficient

Gelation/

Pipeline Restart

Pour Point

Yield Stress/ Pressure

Deposition

WAT

Viscosity

HTGC analysis

Wax Diffusion Coefficient

Hydrate Risk Assessment – Lab Experiments


Temperature: -80 to +250 oC

Pressure: 6,000 psia (400 bar)10,000 psia (700 bar) 30,000 psia (2,000 bar)

Visual Autoclave Rocking Autoclave High Pressure Cell

Run lab experiments under different conditions and plot

experimental points on model hydrate curves

PC – FA Key Collaboration – Corrosion Example


Gas – Condensate subsea pipeline corrosion modelling– Condensation rates modelling

– Relative formation vs condensed water rates over LoF

– Key parameters in water types

• Organic acids content

• Bicarbonate / alkalinity

• pH

• Fe Saturated?

– Corrosion inhibitor screening / qualification in lab

• FA/CE/PC agree P/T, flow rate, ratios, pCO2, pH2S, acetic acid?

• FA supply fluid velocity & pipewall shear stress data – PC then decide optimal test method to screen CI chemicals (vendor / lab input)– LPR, RCE/HPRCE/HPRCA/jet impingement/Flow Loop

– Coupon / segmented weld electrode

– Corrosion rate modelling (Norsok/ECE etc.) - comparison

– Joint interpretation of data – corrosion allowance, CI rate/availability

Any Questions?


Documents

Production Chemistry Networking Event 3 A Holistic Systems ... · Mercaptans, Mercury Desalination, SRP, PWRI, Reuse, Unconventional BS&W, Sulphur, Mercury, Organic chloride Asset