Mika Tienhaara

04.11.2014 RJ

R&D - Technology Development November Conference

RJ, 3-4 November by Innovation Norway

2

GENERAL ASPECTS

3

R&D CENTERS IN WINTERTHUR (DOWNSTREAM) &

ARNHEM (UPSTREAM)

4

INLINE SEPARATION VESSEL BASED SEPARATION

Industry leading design guidelines, based on extensive R&D and testing, involving operators and use of leading multiphase flowloop facilties

SINCE OCTOBER 1 2014 PART OF SULZER

5

Complete Subsea separation toolbox Established through comprehensive testing

(ExxonMobil)

The most comprehensive qualification programme done to date for processing equipment considered for subsea applications

“LARGE PROJECT” - 8 fields generated design conditions input Qualification of all relevant separation equipment and system functionality

6

Fluids: Natural gas, Nitrogen Crude Oil Fresh water, salt water Design Conditions: Pressure: 90 barg ≈ 1305 psig Temperature: 0 – 120 °C ≈ 248 F GVF: 0 – 100% Water cut: 0 – 100% Differential Pressure: 12 bar ≈ 174 psi

Technology Qualification Multiphase Flowloop with Realistic conditions testing

Flowrates: 1200 Am3/hr natural gas 150 m3/hr Hydrocarbon liquid ≈ 22600 BPD 150 m3/hr Water ≈ 22600 BPD Instrumentation: Gas and Liquid reference meters Temperature, Pressure and Differential Pressure transmitters Gas Volume Fraction Nucleonic Level Measurement

Qualification of Processing Equipment and Systems – the industry benchmark (ExxonMobil, Chevron, Total, Statoil, BP, FMC, Aker Solutions ++)

LARGEST FLOW RATE CAPACITY IN THE

INDUSTRY

7

Computer modeling/system design: (CFD simulations) of flow phenomena, forming the basis for understanding of separation mechanism and design correlations

Lab scale Real fluid tests: In specific cases, such as with stable O/W emulsion, lab scale testing can be

important to determine droplet-to-droplet interaction Small scale Model Fluid tests: Measuring and visualizing physical flow phenomena (Hi Speed Video), in

order to verify the validity above models Large scale Model Fluid tests: In order to verify the validity of above design correlations to larger scale

applications Real scale tests: High pressure, realistic flowrates, full hydrocarbon tests, in order to verify

the validity of design correlations and proper operation under field conditions

Technology Qualification steps For successful field implementation and to

minimize risk

ProlabNL/CTAP

ProlabNL/CTAP

ProlabNL/CTAP

Inhouse

e.g. NTNU Ugelstad, UNIFEI

Used by major

IOCs and selected

NOCs

8

Industry cooperation model

MEXICO NETHERLANDS

Multiphase realistic conditions large scale facility

Large-scale facilities that can be used for qualification of processing (separation) equipement and system functionality tests for mature fields, subsea applications,

multiphase flow meters (large scale)

50.000 BLPD / 80.000 MMSCFD / 65 barg Gas/Liquid Separation – Oil/Water Separation – Deoiling – Solids Separation – Gas Treatment

Joint development / Qualification / Training

9

SUBSEA SPECIFIC

10

Subsea Separation interesting for field life extension and increased recovery rates, as well as from robustness and CAPEX aspects Typical solutions • Multiphase boosting • Separation aided boosting

Choice of solution impacts • Topsides design • Flow assurance aspects • Seafloor design

Topsides Reduction in complexity Less equipment / smaller

module sizes

Flow Assurance Minimize gas hydrates risk

Absorbs transient flow condition

Subsea Robust, static equipment High efficiency operations

Benefits of Subsea Separation

Subsea Solutions Use of ´´known´´ complex solutions OR ´´novel´´

simplified solutions

REMARK / All subsea separation projects have undergone a TQP / Tordis, Pazflor, Perdido, Marlim...Field specific!

11

Feed Multiphase Pump

To Host

Multiphase Inlet Gas-Liquid Separation

Gas

Pump

Compressor

Liquids

Sulzer Boosting Solutions Flow Assurance

• Gas hydrates? • Need for hydrate inhibition? • Dedicated risers for gas and

liquids respectively? • Slugs ? • Pumping capacity/Energy ?

Subsea Boosting

Field economics ? Qualification needs ?

12

DEEPWATER JIP A spherical vessel type separator is

beneficial from mechanical design and properties compared to a cylindrical

vessel. Wall thickness can be significantly

reduced.

The Spherical Separator is developed as a

Joint Industry Project Chevron

ExxonMobil GE Oil&Gas

Benefits of the sphere • Reduced wall thickness • Allows for deepwater

deployments • Tolerates slugs • “Compact” • Can be one of the key

solutions for Gas/Liquid separation as well as more economic than PipeSeparator for O/W separation

• Field economics/feasibility

• Open for further participants from phase 2

• Presented at Rio Oil&Gas, DOT, UTC etc

EXAMPLE - Spherical Vessel Separator Joint Industry Project for Deepwater Applications

G/L O/W

PATENT PENDING

13

Primary Separation and L/L Separation Slug Catcher, Desander, Coalescer Separator: inline, pipe, conventional, sphere

G/L Separation

Desander Bulk deoiler Hydrocyclones

Sand Removal & transport

Fines Removal

Reject handling/routing

Gas

Oil

Water

Solids

Subsea Separation Toolbox Qualified Equipment

14

Conclusions

• Large scale realistic conditions testing required to minimize risks and to understand processing equipment behaviour and performance

• Further R&D required for the increased complexity of O&G fields • Importance of cooperation between Oil Company / Integrator /

Technology Provider AND Academia • Ensure local content by involvement and training of local industry

and academia • High technology capabilities and enabler of local content

initiatives

15

THANK YOU! OBRIGADO! TAKK!

tienhaara@ascomsep.com // +31 6 2398 3676