Pushing the oil recovery factor (OMC 2011)How can ultra compact separation solutions help?

March 24th 2011, Ravenna, Italy

Erica de Haas erica.dehaas@fmcti.comFMC Technologies/CDS Separation Systems

CDS Separation Systems – Technology areasp y gy

Conventional separator vessel internals

InLine separation (gas/liquid, liquid/liquid & solids)

InLine Electrostatic CoalescerInLine Electrostatic Coalescer

Produced water treatment

Sand handling (InLine & vessel internals)

Ultra compact InLine separation systems (incl subsea)

Test facilities & modeling capabilities

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Ultra compact InLine separation systems (incl. subsea)

How can ultra compact separation help? How can ultra compact separation help? E h i b fi ld il d bli fi ld d lEnhancing brownfield oil recovery and enabling greenfield development

• Brownfield challenges– Constrained topside facilities

– Increased water production

– Declining oil & gas production– Declining oil & gas production

• Green field challenges– Heavy oilHeavy oil

– Low reservoir pressure

– Hydrate formation

IOR ith l i ti

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• IOR with cyclonic separation

InLine cyclonic separation technologyy p gy

• Stokes:dcs

s

gdv

µρρ

18*2 −

=dµ18

Cyclonic technologyswirling flow

Swirling flow

gincreased G-force

decreased residence time d d f d hdecreased footprint and weight

increased safety, decreased inventory

pipe code

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pipe code

InLine separation technology solutionsp gy

Case Challenge TechnologyLong-offset gas transportation pipelines

Large ∆P due to multiphaseflow

DeLiquidiser*

FLNG with solids Erosion in flexible riser DeSanderFLNG with solids Erosion in flexible riser DeSander

Cold transport Hydrate formation indeepwater pipelines DeWaterer*

S b i H d t tiSubsea processing

Debottlenecking

Hydrostatic pressure

Space & weight constraintsInLine systems

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Long offset gas transportation pipelines g g p p p

• Multiphase flow– Vibrations

– Unstable flare & flaring penalties

– Large ∆P– Large ∆P

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InLine gas liquid separation equipment fl i ivs. flow composition

InLine DeGasser InLine PhaseSplitter InLine DeLiquidiser100 %

100%

Liquid from gasGas from Liquid

80 %

60 %

40 %

100%

ffic

ienc

y

I i GVF t i l t

Set Point

Liquid from gas

90 92 94 96 98 100

Gas from Liquid20 %

0 %

10 20 30 40 50 60 70

90% 100% 0% 60% 20% 95%

0%

Ef

Increasing GVF at inlet

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InLine DeGasser – Application – Statoil S fj d B N S b 2003Statfjord B, Norway, September 2003

Process: Produced water expansion 60 bar 6 bar

Challenge: – Free gas in the system

• Pipe vibrations• Pipe vibrations• Unstable flare control

Solution:– Install 18’’ InLine DeGasser

• Decrease slug flow

Additi l b fitAdditional benefit:– Re-use gas instead of flaring

• 2.3 mln euro in tax savings (CO2 emission)g 2

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InLine PhaseSplitter – Application – Statoil V l f ikk N 2004Veslefrikk, Norway, 2004

VFA VFBOriginal setup VFA VFB

10 barg

Inlet separator

10 barg

Prod. header@16 barg

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InLine PhaseSplitter – Application – Statoil V l f ikk N 2004Veslefrikk, Norway, 2004

• Production header pressure decrease 2 bar

• Corresponding increase in production

VFA VFBGas lines

After implementation

I l t t

10 bargInLine PhaseSplitter

Inlet separator

Prod. header@14 barg

Liquid lines

10

@14 barg

InLine Deliquidiser – Application – BP ETAP U i d Ki d M 2003ETAP, United Kingdom, May 2003

• Location: Upstream HP gas cooler discharge drum

• Flow rates: 554 MMSCFD & 56.9 m3/h (water + HC) (62barg)

Before installation

• Condensate carry-over

After installationLxWxH = 4.1x0.5x4.3mWeight = 4208kg

• System availability 97% (from 26%)

• Water dew point export gas -52°C (from -20°C)

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InLine separation technology solutionsp gy

Case Challenge TechnologyLong-offset gas transportation pipelines

Large ∆P due to multiphaseflow

DeLiquidiser*

FLNG with solids Erosion in flexible riser DeSanderFLNG with solids Erosion in flexible riser DeSander

Cold transport Hydrate formation indeepwater pipelines DeWaterer*

S b i H d t tiSubsea processing

Debottlenecking

Hydrostatic pressure

Space & weight constraintsInLine systems

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Debottlenecking/subsea processing A li i f l i h lApplication areas for ultra compact separation technology

Tordis• Brownfield• Gas/Oil/Water/Sand Separation• Boosting

Pazflor

Perdido• Greenfield• Gas/Liquid Separation• Boosting

Pazflor• Greenfield• Gas/Liquid Separation• Boosting

Marlim• Brownfield• Gas/Oil/Water/Sand Separation

BC-10• Greenfield• Gas/Liquid Separation• Boosting

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Debottlenecking Ultradeep waterFloating LNGArctic

InLine separation – Subsea processingp p g

• Subsea separation progression– shallow water

– ultra depths (>1500m)

Marlim, 2011

InLine separation & water re-injection Pilot application, intermediate step to

Tordis, 2007

cyclonic inlet device, gas by-pass & water re-injection decrease vessel

pp pultra depths

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water re-injection decrease vessel volume by 53%

Subsea InLine separation skid – MarlimB il d 2011

• Sand is recombined with oil & gas and produced to surface

Brazil, start up expected 2011

• Water is re-injected

• Separation components – Inlet InLine DeSander

– Gas harp

PipeSeparator– PipeSeparator

– Outlet section

– InLine water DeSander

– InLine HydroCycloneInstalled @ 900 m

API 21 25°API ~ 21 - 25°

Tekna case study – Debottleneckingy g• Early life

– Oil: 66.000 bbl/d

• Late life– Oil: 12.600 bbl/d

– Water: 9.450 bbl/d– Gas: 35.3 Mscf/d

Water cut: 12.5%

– Water: 62.900 bbl/d– Gas: 35.3 Mscf/d

Water cut: 83.3%Water cut: 12.5% Water cut: 83.3%

1st stage separator

2nd stage separator Electrostatic separator

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Tekna case study – Debottleneckingy g• Early life

– Oil: 66.000 bbl/d

• Late life– Oil: 12.600 bbl/d

– Water: 9.450 bbl/d– Gas: 35.3 Mscf/d

Water cut: 12.5%

– Water: 62.900 bbl/d– Gas: 35.3 Mscf/d

Water cut: 83.3%

MPMInLine DeGasser

Water cut: 12.5% Water cut: 83.3%

InLine PhaseSplitter2 x 10”

2 x 6”

InLine ElectroCoalescer8” & 6”

InLine DeWaterer21 & 10 liners

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Tekna case study comparison O i i l d i Ul d i

1st stage separator

Original design vs. Ultra compact design

1 stage separator

Electrostatic separatorElectrostatic separator2nd stage separator2nd stage separator

Conventional InLine skidConventional InLine skid

Dimensions [m] 13 x 3.5 (1st stage sep.)3 x 8; 3 x 12

14 x 3 x 6

Total operational weight [T] 212 10 7

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Total operational weight [T] 212 10.7

Pushing the oil recovery factor How can ultra compact separation solutions help?

Market trends Ultra compact solutionsMarket trends• Increase production

• Extend field life time

Ultra compact solutions• Debottleneck separation capacity

• Decrease pressure drop

• Reduce OPEX

p p

• Reduce costs– Maintenance

– Inspection

– Boosting

– Heating

• HSE

g

• Reduce inventory

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We put you First, and keep you Ahead

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