first world wide subsea raw seawater injection system …possibility.no/utc2008/ps/g3 nils...
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First World Wide Subsea Raw SeawaterFirst World Wide Subsea Raw SeawaterInjection System in Operation on CNR’s Columba E FieldInjection System in Operation on CNR’s Columba E Field
Nils J. Vågen
Framo Engineering
Columba E – First Raw Seawater Injection System
• PROTECTIVE STRUCTURE & FRAMO DUAL PUMP STATION INSTALLED MAY 2006
• PUMPS DELIVERED JUNE 2007
START UP JULY 2007• START-UP JULY 2007
Framo Dual Pump Station PROTECTIONStation PROTECTION
STRUCTURE
SUBSEA RAW SEAWATER INJECTION SYSTEM
Pump Power and Control System
A cost effective alternative to ti l t id tconventional topside water
injection system
Umbilical
Water Injection Pump
Filter
CONVENTIONAL PLATFORM MOUNTED WATER INJECTION SYSTEM
CHEMICALSDE AERATOR
•expesive Topside Water Injection System including pump with filter, de-aerator, piping,
l ill
COARSE FILTER
BACKFLUSH /SAND FILTER
DE-AERATOR
BOOSTER PUMP
WATERINJECTIONPUMP
valves, etc. will generate
• extra Interface Engineering
i l f difi i / i
PIPE
PLATFORM
•expesive Platform modifications/extensions
•expesive Platform installation, hook-up and commissioning work
PLATFORM•extra space & Weight requirement
•expesive high pressure water injection i liLIFT PUMP pipeline
PIPE TO WI WELLPIPE
SUBSEA RAW SEAWATER INJECTION SYSTEM
SUBSEA RAW SEAWATER INJECTION SYSTEM
TOPSIDE CONTROL SYSTEM
PLATFORMPLATFORM
bili lumbilical
PIPE TO WI WELLFILTER
CHEMICALS
WATER INJECTION PUMP
PIPE
DUMP VALVE
Columba E Location
Water Injection Objectives
• Provide WI support to E-2 and E-5 producers • Add reserves and accelerate production
E4E1Z E2 E5E2
E3YE5
E6 E7
ODT 12473ft TVDSSODT 12473ft TVDSS
Subsea Water Injection System
Topside – Ninian S. Platform•Power & Control module on the host platform• New chemical injection package
Fib ti b d t ti• Fibre optics based automationand control system
•Subsea• 8km Power and Control umbilical
S b F D l t ti• Subsea Framo Dual pump station• 2 x W.I. pumps• 2 x 100% filter unties2 x 100% filter unties• 1 x subsea control module
• 2 x 6” flexible flowlines to XT’s• 4 x controls jumpers• 2 x 10k subsea XT’s
Process Diagram
Filter backwashFilter A
80 microns
Filter backwash
Inlet strainerFilter B
Wi pump 1 Wi Pump 2
M M
Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass
y , y ( )
Max flowrate 63,000 bbl/day at 222 bargMin flowrate 18,000 bbl/day at 390 barg
FDS in Protection Structure
Protection structure: L x W x H = 23m x 10 x 6.5
Weight = 110 T
Pump Module: L x W x H = 8m x 7 x 5.5
Weight = 100 T
FDS In Protection Structure
FDS Components
WI Pumps By-pass Valve Insert
Filter Units Control Pod
8 x 6 x 7m8 x 6 x 7mCirca 110te.
Process Diagram
Filter backwashFilter A
2 x 100% FiltersFilter backwash
Inlet strainerFilter B
Wi pump 1 Wi Pump 2
M M
Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass
y , y ( )
Filter
filtrationfiltration
backwashbackwash
Subsea Water Injection System
•Subsea•Subsea Framo Dual pumpSubsea Framo Dual pump station
• 2 x W.I. pumps• 2 x 100% filter unts• 1 x subsea control module
Process Diagram
Filter backwashFilter A
Filter backwash
Inlet strainerFilter B
Wi pump 1 Wi Pump 2
M M
Duty flowrate 35,000 bbl/day (331m3/hr) & 320barBypass
y , y ( )
Norsk Hydro - Troll Project First Subsea Water Injection Pump (Produced Water)
Framo Engineering have generatedFramo Engineering have generated more than 800,000 hrs
of Operating experience for subsea pumps
Subsea Retrievable Water Injection Pump
• Motor rating 2.3 MW
• Design Speed 3600 rpmDesign Speed 3600 rpm
• Design Capacity 360m3/h @ 3600 rpm
• Rated dP typical 160 bar
• Design pressure 400 bar
• Height 5 m
W i ht 20 T• Weight 20 T
• Oil submerged electric motor
• Centrifugal pump designg p p g
• No dynamic seals to environment
• Retrivable from light intervention vessel
Subsea Water Injection System
•Subsea•Subsea Framo Dual pumpSubsea Framo Dual pump station
• 2 x W.I. pumps• 2 x 100% filter unts• 1 x subsea control module
Subsea Pump Control System SEM Configuration
SEM ConfigurationSEM Configuration• Up to 36 process sensors• Up to 30 solenoid valves• Up to 12 Serial interfaces• Up to 12 Serial interfaces• 600 Watt for external power supply• Configuration is flexible due to open architecture
Key Specifications• Bandwidth Fiber Optic: 100 Mb / 10 Mb• Redundant communication paths• Redundant communication paths• Electromagnetic noise immunity• Power consumption: 100 Watt • Temperature 0 to 50 °C (-20 to 50 °C storage)Temperature 0 to 50 C (-20 to 50 C storage)• Water depth down to 3000 meters
Designed and built to:Designed and built to:• ISO 13628 Part 6
Installation / Stack-up Test
Umbilical
8km Power and Controls8km Power and Controls umbilical
Power & Control Umbilical8km
Umbilical Installation
Umbilical loaded out -Rosyth
Platform termination pulledin – Ninian South
S b T i tiSubsea Termination Unit deployment
Topside Power & Control Module
Topside – Ninian S. Platform•New 90 tonne power & controlNew 90 tonne power & control module on the host platform• New chemical injection package• Fibre optics based automationand control systemand control system
Topside Power & Control module installed on Ninian South
split in 3 parts
PCM Installed topside on Ninian S
System Integration Testing
Topside – Ninian S. Platform•New 90 tonne power & control pmodule on the host platform• New chemical injection package
Fib ti b d t ti• Fibre optics based automationand control system
•Subsea• 8km Power and Controls umbilical• Subsea Framo Dual pump station
2 W I• 2 x W.I. pumps• 2 x 100% filter unties• 1 x subsea control module
• 2 x 6” flexible flowlines to XT’s• 4 x controls jumpers• 2 x 10k subsea XT’s
Columba E – First Raw Seawater Injection System
• PROTECTIVE STRUCTURE & FRAMO DUAL PUMP STATION INSTALLED MAY 2006
• PUMPS DELIVERED JUNE 2007
START UP JULY 2007• START-UP JULY 2007
Framo Dual Pump Station PROTECTIONStation PROTECTION
STRUCTURE
Project Qualification & System Testing
Corresponding tunnel
Subsea Test Dock
Deep Water Quay
System Integration (SIT) – Dry Dock
System Integration (SIT) – Wet Dock
Structures Installation
Structure Loadout Barge - Norway
Pump station Deployment
Protection Structure Deployment
Project Schedule – Sanction to Start-up
• Sanction Feb ’05
• Pump station & umbilical installed May ‘06
• Topsides PCM Installed Oct ‘06 p
• Drilling commencement Nov ’06
T id S t P i i i C l t M ‘07• Topsides System Pre-commissioning Complete Mar ‘07
• Drill & Complete WI Wells May ‘07
• Subsea Hook-up end May ’07
• Subsea & Full System Commissioning Jun ‘07
• Water Injection start up Jul ‘07• Water Injection start-up Jul 07
FRIEND® (FRamo Interactive Enabling Diagnostics)
Internet Service Provider
FE Sandsli
Subsea St tiStation
Online connection between Framo Control Room and Customer SiteCondition monitoring through Real-time streaming of Quality DataInteractive Engineering Applications availableCommunication Functionality Documents & Status ReportsCommunication Functionality, Documents & Status Reports
All made available through dedicated Client FRIEND® Web Portal
Summary - Conclusions
• RSWI a viable solution• increase in injection capacity• minimised impact on existing facilities• re-deployment possible?
• Robust proven technology – a new applicationRobust proven technology a new application• reliable – 100% uptime since start up one year ago• in depth qualification of “new” elements
Summary - Conclusions
• Take the opportunity of high specification• e.g. single controls system• supports economic viability• simpler, efficient interface
• Mitigating project risksMitigating project risks• key elements with a single “system provider”• additional extensive testing performed filter and SCM• comprehensive SIT, wet & dry test (Framo Subsea test
d k) d h diff ”T ti b d thdock); made a huge difference. ”Testing beyond the normal; built operational confidence”
Summary & Conclusions
• Operations from the beginning• Intervention designed in….• Operations involvement with comprehensive training• Life time support: FRIEND
• RelationshipsRelationships• CNR and Framo worked closely to resolve challenges